ME T A LLU R G Y

LE A ]

H . o H OFM AN , E M
. . .
,
E .
,
PH D . .

PRO M O ! Ol ‘
M AI -LUI G Y, I M AM - TI" . mm ! OI '
T E CH N O LO G Y

T man I n m mN p ss

McG RAW H ILL B OO K COM PAN Y, IN C

— .

NE W YORK : 370 SEVE NTH AVENUE

LOND O N : 6 a; s BO U VE RIE ST ” E c 4 . .

1918
 t
a

J L H OF MAN
. .
 P RE FA CE

Si nce the last evi si on of m

r y tre ati se T h e M et a ll u r
,
gy of L e a d and the

D es il veri za ti o n of Base B ulli o n p hysi cal and chemi cal research has gi ven
,

preci si on to the knowledge of the prope rti es of lead i ts alloys and com ,

p o u n d s a
,
n d of m an y met a ll u rgi cal reacti ons; the character of the ores treated
has changed ; blast roasti ng has revoluti o ni zed the details of the treatm ent of
lead ores ; the re covery of values from i ntermedi ary products has bee n modified ;
th e ordi nary practi ce of desi lveri zati on of lead bu lli on has been al tered and i n

p art supp leme n ted by e le c tr o ly si s .

In u nde rtaki ng to prepare a newedi ti o n i t w as found th at by far the larger

part of the book had to be rewri tten and the remai nder altered to a consi derable
,

e x te nt The present work has become a newbook I t retains o nly the chap
. .

ters deali ng wi th reverberatory smelti ng of lead ore s and wi th German cup ella
ti on i n about thei r ori gi nal fo rms While the smelti ng of sulphi de lead ores i n
.

the reverberatory furnace has become absol ete wi th the adve nt of blast roast
i ng the trea tment of the i nte rmedi ary produ cts of a refinery i n the furnace has
,

g row n i n i mport an ce I t seemed

. adv i sa bl e to ret ai n th i s cha pter w hi ch i n ,

addi ti o n to the chemi stry of the proce sses cont ai ns mu ch i nform ,

ati o n of p rac

ti cal value The reason that prompted the retenti on of Germ an cupellati on
.

was that cupe llati on as a process can not be studi ed sati sfactorily wi th E ngli sh
cupell ati o n whi ch has become the ge ne ral m
,
ethod of worki ng The parts deal .

i ng wi th rece i vi ng wei ghi ng and sam

, ,
pli ng of ores have been omi tted as they ,

have been thoroughly di scussed elsewhere .

Si nce 1 89 2 I have revi ewed annu ally i n th e Mi neral Industry the prog re ss
that has been made i n the metall urgy of lead and lead silver and have thu s -

remai ned in tou ch wi th what i s goi ng on i n thi s branch of metall u rgy As a .

study of the techni cal li terature i s i nsuffi ci e nt for thi s pu rpo se the le adi ng lead ,

plants of the Uni ted States and Canada have been vi si ted The u p ortance .

of such a study becomes evi dent whe n the drawi ngs and worki ng data gi ven
in the present book are compared wi th tho se co ntai ned in the p recedi ng edi ti o n .

I desi re to e xpress my Obli gati on to the Am eri can S 81 R Co Bal bach . . .

,

S 8: R Co Consoli dated M 8: S Co of C anada E agle P i cher Lead Co

. . .
, . . .
,
-
.
,

Internati o nal 8 Co N orthport S 8: R Co St Loui s S

. .
,
. . . R Co and
,
. . . .
,

IX
 PREFACE

Uni ted States S R 8c M Co

. . . .
,
for the
pri vilege of studyi ng their vari ous plants ,

and to the ofi cers at the wo rks for the i nte rest th ey have shown in m y ende avo rs ;
al so to seve ral m anufactu ri ng firms for the pe rm i ssi on to use a number of th ei r
b luepri nts In looki ng at th e fini shed treati se i t becomes evi dent that wi thout
.
,

thi s assi stance f rom th e works the aimto wri te a book whi ch represents modern
,

practi ce could not have been attai ned .

In carryi ng out calculati o ns and i n see ing the book through the press I
,

have had the assi s tance of P rofesso rs C R H ayward G A Roush and H L

. .
, . .
, . .

Seave r.

H . O H ornAN
. .

MASS ACHU SE TTS I N srrrurn or TE CH N OLOGY,

C m nmc s, MAss ,. August , 1 91 8
.
 CO N T E NTS

PRE PACE

CHAPTE R I

I NTR ODU CTI ON

rp hy
.

1. Hi stori cal N ot1ce , 1 ; 2. Sta t ist i cs, 4 ; 3 . Bi bli og a , 6

.

CH APT E R I I

PRO PE RTI E S OP LE AD
4 . Physi cal Prop erti es, 7 ; 5 . m
Che i cal Prop erti es, 11 .

CHAPTE R III

LE AD COMME RCE , ITs I MPU RITIE S AN D T H E IR E PPE crs

or

6 Grades of Lead, 1 3 ; 7 I p uri ti es and Th ei r Efi ects, 1 5 ; 8 Cop p er, 1 5 ;

. . m .

9 .Silver,
C opp er and Silver, 1 7 ; 1 1 Go ld, 1 7 ; 1 2 Bi s ut h , 1 7 ; 1 3 Cad . . m .

mm . . m
i u , 1 8 ; 1 4 Ti n, 1 8 ; 1 5 Anti ony, 1 9 ; 1 6 Arseni c, 2 o ; 1 7 N i ck el and Cobal t , . .

2 0 ; 1 8 I ron, 2 1 ; 1 9 Zi nc, 2 1 ; 2 0 Manganese, 2 2 ; 2 1

. . Alu i nu , 2 2 ; 2 2 M inor . . m m .

Metals, 23 .

CHAPT E R IV

INDU STRI AL ALLO YS

2 3. General ,
2 4 ; 24 . Lead A t i mony, -
n 2 6 ; 2 5. Lead -
Ti n , 2 8 ; 2 6. Lead Anti m
-
ony -
Ti n
,

30 ; 2 7 . Lead Arseni c, 33 ;
-
2 8. Other Lead Alloys, 33 .

CHAPT E R V
LE AD CO MPO U NDS
29 . Lead Oxi de and Carbonate, 34 ; 30 Plu bi tes and Plum bates, 3 6 ; 3 1 Lead Fer . m .

ri te, 3 6 ; 32 Lead Sili cates, 3 7; 33 Lead Borates, 3 8 ; 34 Lead Chlori de, 3 8 ; 35 Lead
. . . .

m
Bro ide and I odi de, 39 ; 36 Lead Fluori de, 39 ; 37 Lead Fluosi li cate, 4 o ; 38 Lead
. . .

Seleni de and Tell uri de, 4 o ; 39 Lead Sulp hi de, 4 1 ; 40 Lead Sul p hate, 45 ; 41 . . . Reac
ti ons between Lead Sulphi de, Oxi de and Sul phate, 4 7 .

CHAPT E R VI

42 Int roducti on, 4 9 ; 43

. , G . Lead
4 9 ; 44 A n l —
Mi nerals
g esi te Cerussi te, 5 1 ; alena, .

45 O t.he r L ea d M i ne ral s, 53 ; 4
6 L e ad O r es of t he U n i ted St a t es, 53 ; 47 Atlanti c
. .

Coast , 53 ; 48 Missi ssi pp i V all ey, 54 ; 49 Rocky M ountains, 55 ; 50 Paci fic Coast,

. . .

8
5 ; 5 1 P u rcha s i n g L ea d Silv e r Ores 6o ; 5 2 Pu rch a si ng N on ar g en tiferous Ores, 65 ;

m
- -
. .
,

53 M e
. tall urgi ca l T rea t e n t i n G en e ral , 66 .

x1
xi i CON TE N TS

CHAPT E R VII

SN E LTI N C LE AD ORE s I N THE RE VE RBE RATORY FU RN ACE

54 .
55 O
Int roducti on, ut li ne ,
6 7 ; 5 6 Pro d ucts , 6
6 7;8 ; 57 L i
. i tati ons, 69 ; . . m
58 I n
.fluence of Foreign M at ter , 6 9 59
; C lass ificati on o f Re v e rberat or y M et hod s, 71 ; .

60 The Cari nthian M ethod, 7 2 ; 61 The E ngli sh M ethod, 77; 62 The Silesi an
. . .

Method, 86; 63 Comp ari son of Reverberat ory Methods,

.
92 .

CHAPT E R VIII
S ME LTI N G LE AD 021 18
'

IN THE ORE HE ARTH .

64 I ntroducti on, 96 ; 65 I nfluence of Foreign Matter, 9 7 ; 66 Furnaces, 9 8 ,

. . .

67 Mode of Op erating, 1 07 ; 68 Plants, 1 1 0 ; 69 Exa ples of S elti ng 1n the Ore

. . . m m '

Hearth, 1 1 5 ; 70 Products and Thei r Di sp osal, 1 1 5 ; 71 Cost, 1 2 1 ; 72 Lewi s and

. . .

m
Bartlett or Subli ed Lead Process, 1 2 1 ; 73 F L Bartlett Process for the Treat ent
-
. . . m
of m
Co p lex Zi nc Lead Sulphi des, -
1 28

CH APT E R IX

SM E LTI N G LE AD ORE S I N THE BLAST FURN ACE

A ROASTIN O
. AND BLAST ROASTI N C

74 I
. ntroducti on, 1 6
3 ; 5
7 O x i di z i ng Roast of Metalli c Sul p hi des i n
. Powder For , m
1 3 8; 76 Roasti ng, General, 1 4 0 ; 77 Roasti ng Furnaces, General, 1 4 1 ; 78 Oxi di s i ng
. . .

Roast of Metalli c Sulphi de i n Reverberatory Furnace, 1 4 3 ; 79 Long bed Reverbera .

-
.

tory Hand roasti ng Furnace, 1 4 5; 80 Reverberatory Hand roasting Furnace w

-
i th .
-

Level Hearth , 1 4 5 ; 8 1 Reverberatory Hand roasting Furnace w i th Slaggi ng Heart h

.
-

or Fuse box , 1 50 ; 82 -
Reverberatory Hand roasting Furnace w i th Si nter hearth ,
.
- -

1 54 ; 83 Products of Reverberatory Hand roasti ng Furnaces, 1 54 ; 84 Blast Roasti ng,

.
-
.

General , 1 56 ; 85 Theory of Blast Roasting, 1 58 ; 86 Pri nci ples Governi ng Make up

. .
-

of Charges, 87 Manage ent of Furnaces, General, 1 63 ; 88 Rough

1 60 ; . m .
-
roasti ng
Metalli c Sulphi de for Blast Roasti ng, 1 64 ; 89 Brunton Furnace, 1 64 ; 90 . . Godfrey
Furnace, 1 65 ; 9 1 . H olthofi Furnace, 1 70; 92 . Wedge Furnace, 71 ; 93 unti ngt on 1 . H
H eberlei n Process , 77 ; 94 O th er For s of Up d raf 1 . m -
t Blast Roasti ng Po ts and Proc
esses, 1 84 ; 9 5 . m
Car i chael Bradfo rd Process , 1 87 ; 9 6 Savel sberg Process, -
. 1 88 ;

97 D w. i gh t Lloyd Process, 1 9 0; 98 D w
-
i gh t Lloyd Strai gh t li ne Machi ne, .
- -
1 91 ;
99 General Arrange ent of D w
. m
igh t Lloyd Plant, 2 03 ; 1 00 D ouble Treat ent , -
. m 2 04 ;

1 01 . Co mparison of Hunti ngton Heberlei n and Dwi ght Lloyd Processes - -

,
2 06.

B . BLAST FURN ACE S

1 02 . Raw Materi al s and Products, General, 2 07 ;

Blast Furnaces, H andli ng of

1 03 Foundati on, 2 1 0 ; 1 04 Shaf t, 2 1 3; 1 05 Hei ght , 2 1 3 1 06 Hori zontal Secti on,

. . . .

2 1 3 1 07 Vertical Secti on, 2 23 ; 1 08 Buildi ng Materi al , 2 2 3 ; 1 09 Feedi ng and Gas

. . .

wi thdrawi ng Op eni ngs, 2 2 6 ; 1 1 0 Hearth wi th Arents Auto ati c or Si phon Tap , 2 3 2 ; . m

111 W ater jack ets, 2 35 ; 1 1 2 Tuyeres, 2 38; 1 1 3 Blast, 2 4 3 ; 1 1 4 Handli ng Ores,
.
-
. . .

Fluxes and Fuels, 2 4 5 ; 1 1 5 Handli ng Lead, 2 55 ; 1 1 6 Poli ng Lead, 2 5 7; 1 1 7 Hand

. . .

li ng Matte and Slag, General, 2 58 ; 1 1 8 Separati on of Matte and Slag, 2 59 ; .

1 1 9 H andli ng of Mat te, 2 69 ; 1 2 0 Handli ng of Slag, 2 78 ; 1 2 1

. Re oval of D ust and . . m
Fu me f mFurna e Buildi ng
ro c , 2 86 ; 1 2 2 . Blast Furnace Plant, 2 90 ; 1 2 3. Fuels, 2 99 ;

1 24 . Coke, Charcoal , 30 1 ; 1 2 6 Coke and Charcoal, 30 2 ; 1 2 7 Cok e and

2 99 ; 1 2 5. . .

m
B i t u i nous Coal 30 2 ; 1 2 8 Cok e and Anthraci te, 303 ; 1 2 9 Li qui d and G aseous Fuel,
. .

m m
,

0
3 4 ; 1 30 W ei gh t of Fu el. 0
, 3 4; 1 3 1 L ead Sla s
g , Ther oche i cal Prop ert i es, 307; .
 CON TE N TS xii i

1 32 . Ther mphy i
o s cal Properti es, 3 1 1 ; 1 33 . Physi cal Properti es, 31 3; 1 34 .

Fluxe
s , I ron, 3 1 5 ; 1 36 Manganese, 3 1 6 ; 1 37 Li e, 3 1 7 ;
Sili ca, 3 1 5; 1 35. . . m 1 38 .

. m
M agnesia , 3 1 9 ; 1 39 Alu i na, 3 1 9 ; 1 40 Fluorsp ar, 3 2 2 ; 1 4 1 Slag, 3 2 2 ; 1 42 . . . In
fluence of Forei gn Matter, Gyp su , 3 2 3 ; 1 43 Bari te, 3 2 3 ; 1 44 Blende, 3 2 5 ; m . . 1 45.

Zi nc Oxi de, 3 2 6 ; 1 46 Pyri te, 3 2 8 ; . Chalcop yri te, 32 8 ; 1 48 Anti ony, 3 2 9 ;

1 47. . m
1 49 Arseni c, 3 2 9 ; 1 50 Calcula ti on
. . of Charge, G eneral , 330 ; 1 51 Calcul ati on of .

Charge by Algebrai c Method, 33 1 ; 1 52 Calculati on of Charge by t he M ethod of .

Proporti ons, 33 6 ; 1 53 Che i stry of the Blast Furnace, General, 339 ; 1 54 Ascend
. m .

ing Gas Current, 3 4 1 ; 1 55 D escendi ng Ore Charge, 34 3 ; 1 56 Ther al Bal . . m

ance, General , 34 5; 1 57 Rati onal Analyses, 34 5 ; 1 58 D i stri buti on of Materials, 34 5 ;
. .

1 59 Calculati on of Ther al Balance for a Charge, 34 8

. m .

C OPE RATI ON S
.

1 60. Smelti ng Operati ons General , , 3 51 ; 1 61 . Blowi ng i n, -

General , 35 1 ; 1 62 . h ad

melti ng Method, 35 2 ; 1 63 PlatformMeth od, 355 ; 1 64 Lead charging method 356; . .

-

1 65 W ork on the Chargi ng Floor, 357; 1 66 Mechani ca l Feedi ng, 3 57; 1 67 Pueblo
. . .

System 3 58 ; 1 68 East Helena Syst em 362 ; 1 69 D arby T hi m

, . ble Method 368 ; , .
-

1 70 W ork on the Furnace floor, 368 ; 1 71

. W ork on the D um p 3 70 ; 1 72 I rregul ari -
.
, .

ti es i n the Blast Furnace, 3 71 ; 1 73 . Blowi ng out , 3 76; 1 74 . Fu m oe a and Assay Book s ,

3 77

D . B LAST FU RN ACE PRODUCT S

1 75. t he Blast Furnace, 3 79 ; 1 76 So t Lead and Lead Bulli on, 3 79 ;

Products of . f
1 77 Sp ei ss, 3 85 ; 1 78 Treat ent of Sp ei ss, 38 8 ; 1 79 Matte, 39 2 ; 1 80 Consti tuti on
. . m . .

O f Mat te, 39 3 ; 1 8 1 Treat ent of Matte, eneral, 4 00 ; 1 82

. Roasti ng and Blast m G .

Roasti ng of Matte, 40 1 ; 1 83 Concentrati on, S elti ng of Roasted and Blast Roasted . m

M at te i n Concent rati on S elting of Roasted M att e
the Blast Furnace, 4 02 ; 1 84. m
i n the Reverberat ory Furnace, 4 05 ; 1 85 Converting of Lead Copp er Matte, General, .
-

4 07 ; 1 86 Converti ng w i th Addi ti on of Sili ci ous Flux ; Pei rce S i th Vessel , 4 09 ;

.
-
m
1 87 Process and M ani p ulati on, 4 1 1 ; 1 88 Collecti on of Lead Fu e, 4 1 3 ; 1 89 Con
. . m .

verti ng Lead cop p er M at te w i thout Addi ti on of Sili cious Flux ; T ooele, U t ah ,

-

4 1 9 ; 1 9 0 Process and . Mani pulati on

Slag, 4 2 4 ; 1 92 W all Accreti ons, 4 2 5; , 4 1 9 ; 1 91 . .

1 93 Hearth Accreti ons or Sow

. s, 4 2 6 ; 1 94 Furnace Cleani ngs and Furnace Refuse, .

4 2 6 ; 1 95 Furnace Gases, 4 2 6 ; 1 96 Flue or Cha ber dust, 4 2 7 ; 1 97 Recovery of

. . m -
.

m
Flue dust and Fu e, General, 4 30 ; 1 98 Dry Collecti on of D ust and Fu e, 4 30 ;
-
. m
1 99 Cooli ng of Gas, 4 30 ; 2 00 Retardati on of Gas Current and Set tli ng of D ust ,
. .
.

4 34 ; 2 01 Change of D i recti on of Flue, 4 3 5 ; 2 02 Suspensi on i n Flue of Plates at Ri gh t

. .

Angle to Gas current , 4 3 5 2 03 E nl arge ent of Flue to Cha ber, 43 5; 2 04 Al ter

-
. m m .

m
nate E nlarge ent and Contracti on of Fl ue, 4 35; 2 05 Susp ensi on of Plates i n Flue .

Parallelwi th Gas current 4 36 ; 2 06 -

, . Susp ensi on of W i res i n Flue, 4 3 7 ; 2 07 Efii ci ency .

of Dust arresti ng D evi ces 4 3 8 ; 2 08

-

, . Filtrati on of Fu e, General, 44 0; 2 09 Bag Fi l m .

-

t rati on at Murray, U tah , 44 2 ; Solenoi d Bag shaki ng D evi ce, 44 8; 2 1 1 Bag 2 1 0. -

.

Filtrat i on at Mi dvale, U tah , 4 4 9 ; 2 1 2 Sprague Process, 4 53 ; 2 1 3 Baghouse, Gen . .

eral , 4 54 ; 2 1 4 Electri c Preci pi tati on, Cot trell Process, 4 57 ; 2 1 5 W et Condensati on,
. .

. m
4 60 ; 2 1 6 T reat ent of Fl ue dust, 4 60 ; 2 1 7 Losses and Cost , 4 65 -
. .

CHAPT E R X

DE SI LVE RIz ATI O N or LE AD B U LLI ON .

2 1 8. I ntroducti on, 4 6 7 .
 CON TE N TS

A PATTrNS O N PROCE S S
.

2 1 9. Pat tinson Process, General , 4 68 ; 2 2 0. Origi nal Patti nson Process, 4 71 ;

22 1 . Luce and Rozan ( SteamPatti nson) Process, General , 4 72 ; 2 2 2 . Luce and Rozan
Process, Pi i bra '

mB , oh e mi a , 4 73 ; 2 2 3 Luce and Rozan Process, Eureka, N ev

. .
, 4 80 ;
2 2 4. Tredi nni ck Process, General 4 8 1 ; 2 2 5 Plant 48 5; 2 2 6 Crystalli zer 4 85 ;
, .
,
.
,

2 2 7. Schedule of Op erati on ( Newnam System ) 48 7 ; 2 2 8 D etails of an Op era , .

ti on, 4 9 2 ; 2 2 9 . D ross ,
Fuel, Labor, Cost , 4 9 3; 2 30. Thu mP o e r c ss, 494 .

B . PARKE S PRO CE S S

231 . Parkes Process, General , 494 ; 2 32 . Beh avi or of Metals i n Zi nc Desilverizati on ,

4 95 ; Outli ne of Process, 50 2 ;
2 33. 2 34 . Plant, General , 504 ; 2 35 Nati onal S elti ng
. m
and Refini ng Cc , South Chi cago, .
504 ; 2 36 Selby S . m elti ng &Lead Co , Selby, Cal . .

505; 2 37. Internati onal Lead Refini ng Cc , E ast Chi cago, Ind . .
, 50 7 ; 2 3 8. Bal
bach S melti ng , J Refini ng CoO p erat i on, G eneral , 5 1 2 ;
. Newark N , . .
, 509 ; 2 39.

2 4 0 Recei vi ng Lead Bulli on, 51 2 ; 2 4 1

. Softeni ng Lead Bulli on, 51 4 ; Softeni ng .

Furnace, 5 1 8 ; 2 43 Method of W orki ng, 52 3 ; 2 44 D esilveri zati on of Softened Lead

. .

Bulli on, General

, , ; 5 2 8 ; 2 4 5. Gold Zi nc
Silver Zi nc, 53 1 ; 24 7 D esilveri zing -

53 1 2 46. -
.

Ket tles, 536 ; 248 Li quati ng App aratus, 54 2 ; 249 Mode of Conducti ng the Desilveri
. .

zati on and Results, 54 5 ; 2 50 Refini ng D esilverized Lead, General , 55 1 ; 2 5 1. Refin .

i ng D esilverized Lead i n the Reverberatory Furnace , 5 51 ; 2 52 . Refini ng D esilverized

Lead i n the Ket tle, 553 ; 2 53 Moldi ng of Refined Lead, 558 ; 2 54 Labor, Fuel , and
. .

Yi eld of Lead, 565 ; 2 55 T reat ent of Z i nc Crust , General, 566 ; 2 56 D istil lati on of
. m .

Zi nc Crust , General, 566 ; 2 57 Faber du Faur Retorti ng Furnace, 567 ; 2 58 Con . .

densers , 569 ; 2 59 Method of W orking, 573 ; 2 60 Results, 57 7; 2 61 Treat ent of

. . . m
m
I nter edi ary Products, General , 579 ; 2 62 Softeni ng Furnace, D ross and Ski i ng, . mm
579 ; 2 63 Ti n .S k i i n 8
g, 5 4 ; 2 64 K ettle mm
D ross 8
, 5 4; 2 65 R efini ng Ski i ng s a nd . . mm
Poli ngs, 584 ; 2 66 Ri ch Lead and Metalli c Z i nc, 58 7 ; 2 67 Retort D ross and Blue
. .

Po w der, 58 7 2 68 Li tharge, 588 ; 2 69 Old Retorts, Cup el Bott o , E tc , 588 ;

. . m .

2 70 Results and Cost , 58 8 ; 2 7 1

. Records, 588 ; 2 72 Relati ve Advantages of Parkes . .

and Patti nson Processes , 590 .

C CUPE LLATI O N PR OCE S S

.

2 73. Cupellati on, General

59 1 ; 2 74 Ger an Cup ellati on, General , 594 ; 2 75 Fur
, . m .

nace, 59 4 ; 2 76 Pla t tner Cup elli ng Furnace, 59 4 ; 2 77 M ode of Op erati ng, 59 6 ;

. .

2 7 8 English Cupell ati on, General , 60 2 ; 2 79 Furnace, 60 2 ; 2 80 Test Ri ngs, 60 7 ;

. . .

281 . Test Ri ng Support s, 61 0; 2 82 . Hearth M ateri al ,

61 2 ; 2 83 . Blast , 61 4 ;
2 84 . Tools, 6 1 4 ; 2 85 Mode of Op erati ng, 6 1 4 ; 2 86 Inter edi ary Products, 6 1 7 ;
. . m
2 87 Resul ts, 6 1 7 2 88 Loss, 6 1 8 ; 2 89 Co pari son of Ger an and Engli sh Cupella
. . . m m
ti on, 61 8 .

D . BE TTS PR OCE S S

2 90. Bet ts Process, ,

General Current, 62 1 ; 2 93 61 9 ; 2 91 . Electrolyte, 6 2 0 ; 2 92 . .

Anode, 62 1 ; 2 94 Cath ode, 62 3 ; 2 95 Electrode D i stance, 6 2 4 ; 2 96 D ep osi ting Vat ,

. . .

6 2 5 ; 2 97 Corrosi on of Anode and D eposi ti on on Cathode, 63 2 ; 2 98 Anode Mud,

. .

. m
634 ; 2 99 Co p ari son of Bet ts and Parkes Processes, 63 6 .

CH APT E R XI

LE AD POIS ONI N C
300. General , 63 7 ; 301 . Lead and Its Co mpound s as Poi sons, 638 ; 302 . Re medi es ,

63 8 .

I NDEx
 ME TA LLU RG Y O F LE A D

C H APTE R I

IN TR ODUCTIO N

1 . Hi stori cal Noti ceJ —

of the si x so called pre hi stori c metals Le ad i s one -
.

The E gypti ans used o nl y copper i n the fir st prehi stori c peri od

2 —
7000 B C . .
,

long chronology ) ; i n the second ( 7000 5000 gold Silver and lead came in -

, ,

together; i n the 1 8th Dynasty ( 1 600 1 4 00

—
lead became very commo n .

One of the oldest pi eces Of le ad extant is probably th at of a fi gure i n the Bri ti sh

M useum whi ch antedates 3800 B C
8
. .

The P h oeni ci ans called the greatest metall urgi sts of anti qui ty fou nded , ,

C adi z about 2 300 B C They worked the Ri o Ti nto deposi ts i n whi ch silver . .

beari ng gale na occurs i n the go ssan of the pyri te ; th ei r slag dumps are under -

lai n by older slag heaps That they tr aded for lea d i s menti oned i n E z ek i el -
.
,

xx vn , 1 2 .

the li brary of Ashur b ani p al (

In B C ) are fou nd m any bili ngual - - —
668 6 2 6 . .

copi es of Baby lo ni an ori g i nals from about 2 000 B C ; one of these co nt ai ns . .

“
a hy m n to th e fire god —
Gi bi l o f copper and lead th ei r melter art th ou of -

, ,
”4
gol d and si lver thei r p uri fier art thou At Assur ( 1 300 B C ) a block of lead . . .

wi th i nscri pti ons wei ghi ng lb w as found b eneath whi ch were p late s of
,
.
,

gold and si lver Lead must have been a well known metal wi th the H ebrews
5
.
-

as i n E xodus xv 1 0 i t i s sai d that the E gypti ans sank as lead i n th e m i gh ty

, , ,

waters .

The Gr eeks mi ned lead ores on the i slands of R hodes Cyprus and E uboea , ,
.

The silver lead mi nes of Lau ri um i n Atti ca we re i n Operati on before 560 B C ;

-
. .

they flou ri shed 1 00 years later and were consi dered to be worked out at ,

the begi nning of our era I n 1 863 they we re re opened by a French .

-

1
Frantz , “
A , Blei. und Zi nn i mAlterth um ,
B erg . a . H atten mZ . .
,
1 880 , 365, 4 3 7,

Hofmann , K B . .
, D a s Blei bei den V olk ern des A lt erth u s,
H ef t 4 7 2 of Vi rch o w m
H oltzendorfi ’
s Sa mm m
lung ge ei nversti ndli ch er w i ssenschaftli ch er Vortrage, H abel, Berli n,
1 88 5 .

Pulsi fer, W H . .
,
Notes forHistory of Lead
a ,
”
Van Nostrand ,‘
N ew York , 1 888 .

Frei se, Oest Z t B erg u . . . . H attenw 1 90 5 L111 3 54

.
, , , ,
6 7 8 1
3 , 3 3, 39 , 4 0 5, 3
4 6 .

Pet ri e,
“The M etals i n E t
” “
A i t E t 1 2 2 3 ; abstr
— E ng Min
gyp , nc en gyp t , 1 91 5, p . 1 ,
.
,
. .

J . . 1 91 4 , x cv m9 , 12 .

‘ A ri cola
g , G .
,
“De re metalli ca ,
1 6
55 ; t ransl by . Hoover H ,
. C . and L H . .
, Mi ni ng
Magazi ne ,
London, 1 9 1 2 , 390 .

“
D eli t sch , F , Assyri sches H andwOrterbuch , H i nri chs, Lei p si c, 1 89 6, 1 76
.
”
and 2 2 1 .

5 Andrae, Mi tthcilungen der Deutchen Ori ent Gescllschafl, June, 1 9 1 4 , No 54 -

. .
2 ME TALLUM Y OF LE AD

c ompany whi ch erected smel ti ng works and treated newore and the anci ent
1

co nce ntr ati on and slag d umps ; the works are i n operati o n at pres e nt -
.

The Romans worked lead mi nes i n Sar di ni a whi ch had been ope ned up by ,

the t ni ci ans and operated by the C arthagi ni ans and in so u theastern Spa in ,

i n the thi rd century B C ; bo th regi o ns are lead p roducers today Whi le the . . .

Romans spar ed the mi neral res o urce s of I tal y th ey carri ed on mi ni ng opera ti o ns ,

i n conquered countri es ; thus i n Gaul they extracted ore at Vi llefranch e Pont ,

g i ba ud E v reu
,x L illebo nne an d ot h er p la ces ; i n, B ri ta i n ’
i n So mer s ets hi re , , ,

Derbyshi re Shrop shi re etc where they found slag d umps proving that the
, ,
.
,
-

Bri to ns before th em had mi ned and smelted si lve r lead ores I n Germany
'

-
.

some Roman mi nes i n the regi o n of the Rhi ne were opened up betwee n 700

and 1 000 AD the celebrated mi nes i n the H arz mountai ns were di scovered
.

i n 968 those of Saxony Siles ia and Bohemi a about 1 2 00

, , ,
.

At prese nt the Uni ted S tates is th e leadi ng lead producer of the w orld I n .

thi s country lea d mi ni ng da tes as far back as 1 6 2 1 when lead w as m i ned and
8
,

smelted near Falli ng C reek Va Duri ng coloni al ti mes lead mi nes were oper ,
.

ated mai nl y i n N orth C aroli na N ew York and the N ew E ngland sta te s , , ,

but only on a small scale and not very succes sfully The mi nes p ri nci pally ,
.

menti oned are the Washi ngton mi ne Davi dson county N C the Rossi e , ,
. .
,

mine St Lawrence county N Y and the mi nes near Mi ddleton Conn and
, .
,
. .
, , .
,

Southampton Mass N one of th em were worked co nti nuously and at pre sent
,
.
,

there are produced i n the E ast o nl y about tons of lea d of whi ch Oklahom a ,

furni shes over tons the rest comi ng from Vi rgi ni a Tennessee and N orth , , ,

Caroli na .

Lea d ores are supposed to have been fo und i n Wi sconsi n i n 1 68 2 by Perrot ‘

.

T he lea d or es of M i ssouri were di scovered i n 1 700 by Penni ca ut one of Le ,

Sueur s party and were first worked successfully i n 1 72 0 ; M i ne La M otte of

’
, ,

Madi son county whi ch i s worked at p resent was the first deposi t di scovered
, ,
.

I n the Wi sco nsi n I owa regi on the firs t mini ng w as do ne by D ubuque on th e

-

place where the ci ty named after hi m nowstands , ,

.

From these two di stri cts the lower and upper M i ssi ssi ppi Vall ey cam e the , ,

bulk of the lead of the Uni ted States unti l 1 867 when the first great mi nes of
the West were ope ned The total reached to ns i n As the p rod
.

uet of the country w as 5 5 to ns t h e s e d i s tr i ct s fu r ni sh ed n ea r ly 8

3 p er ,

cent of the enti re output

. The rest came from the western states whi ch .

Cordella, Berg u H iale n Z , 1 864 , xx , 2 85, 1 865, xx rv, 2 0 . m m .

m
. . .

Lacroi x , Glack 1 89 7, xxx , 3 ,

1 C he Z Ref» , 1 89 7, xxx, 3 1 m . . .

Georgi ades, Bull I nd M i n , 1 89 7, xx, 52 3 . . . .

E rnst , Oest f ahrb , 1 90 2 , L, 5 ,

0 44 7
m m
. . .

Colli ns, E ng Mi n J , 1 904 , Lxxv , 751 ; 1 905, 12 01131, 363 ; 1 909 , , 88 1 m

m m
. . . .

m
Guilla u e, Ann M i n , 1 909 , xv, 5; E ng M i n J , 1 909 , .
, 44
6 . . . .

“
Hunt, R , Bri tish Mi ni ng, Crosby, Lockwood 81 Co , London, 1 884 , p 2 1
”
. . . .

“
‘ In all
g s, W R ,
Lead a nd Z i nc i n.t h e U ni ted Sta t
.es,
”
McGraw Hill Book Co -
.
, Inc ,
.

NewYork , 1 908
m 4 98
.

Irvi ng, Tr A I . . . M . E .
, 1 880, v ,
.

Mi n Res U . . . S .
, 1 91 5, 1 , 1 87
 I N TROD UCTI ON 3

produce argenti ferous lead ores while those fr om the Mi ssi ssi ppi Valley are ,

non argenti ferous that i s do not conta i n enoug h S ilver to p ay for i ts ex tracti on
-

, , .

The first di scovery of argenti f erous lead ore w as made i n 1 863 i n Li ttle

Cottonwood C anyon Utah ; the first smelti ng of such ores was carri ed on i n ,

1 865 at Argenta M o nt ; i n 1 86 7 si milar ores were found at Whi te P i ne N ev

, ,
.
,

and sme lti ng w as begu n at Oreana N ev In 1 869 the m i nes of E urek a N ev , .

,

di scovered i n 1 864 were ope ned up and the trea tment of ores w as beg un i n
, ,

the followi ng year N e xt came U tah where smel teri es were erected i n 1 870 .
, ,

followed by Co lo rado whi ch came into promi nence in 1 878 Later I daho , .
,

NewM exi co and Ari zona we re added to th e li st , Colorado for many years .

was the larges t producer of lead ores but i t has been outranked by I daho and ,

Utah si nce the exhausti on of the wonderf ul mi nes of Leadvi lle after 1 890 ; i t
furni shes at present only 6 7 per cent of the country s product and thi s hi gh
— .
’
,

figure i s largely due to the ce ntral smel ti ng works of Denver and Pueblo whi ch
treat more lead ore mi ned outsi de of the state than pro duced i n i t .

The manner i n whi ch p rehi stori c people extracted lead from ore i s unknown .

If w e r ecall th at o xi de and sulphi de ore s readi ly gi ve up lea d when heated

wi th charcoal we can i magi ne that the acci dental di scovery of thi s fact may
,

have led to the most pri mi ti ve furnace a small p i t dug i nto the ground and ,

e nclosed by sto nes to form a small shaft If at first such fur naces were wo rked .

by natural draft blast ( reeds bellows) must have been appli ed to pro duce the
m
, ,

te perature req uired to form slag The f urnaces ( cavi ty 30 i n deep si de wall s . .
,
-

2 6 i n hi gh 2 tuy e re Ope ni ngs) found i n Si nai i n whi ch copper ores were sme lted
.
,
-

a bout 4 000 B C had thi s form ; the furnaces of Lauri um were si m i lar In
1
. . .

ea rly ti me s low shaft fur naces wi th natural or for ced draft fo rmed the ap

paratus and charcoal the fuel Agri cola states that i n 1 556 th e i nhabi tants
,
2
.

of the pres e nt Austri an provi nce of C ari nthi a used what may be call ed a closed
s tall w i th i ncli ned bottom for treati ng galena ; they ki ndled a wood fire and
charged the ore upo n i t whereupo n lead w as li berated and tri ck li ng down the , ,

hearth was collected in a basin Si milar co ntri vances the Log furnace and
, .
,
-

As h f urnace were used i n smel ti ng ores i n the Mi ssi ssi ppi valley about 1 72 0
-
”
, .

T hes e were i n operati on until 1 836 when th e first Scotch ere hearth w as erecte d ,
-
.

Percy states that in 1 730 the ore hearth was i n operati on i n Derbyshi re
‘ -

E ngland .

The reverberatory furnace fired wi th coal w

Ii
as first used by Wri ght i n

Fli ntshi re Wales i n 1 698 I ts use i s sai d to have bee n suggested by the Sp an
, , .

“
i sh pri est Alo nzo Barba i n hi s book Arte de los M etales etc publi shed at ,
.
,

Madri d in 1 64 0 I n the E ngli sh tr anslati on by the E arl of Sandwi ch of 1 669

.
,

published by S M es rne Lo ndon 1 674 no su ch sugge sti o n appears but eve n

.
, , , ,

1
Fli nders Petri e, -
W N “Researches in Si nai D utton 81 Co . N ewYork , 1 906, 2 4 2
. .
, , , .

3 Op . ci t , 390 .

Ingal ls, op ci t , p 96 . . .

“ ”
Lead, 2 1 6 .

Schltl ter, C A , . . Gri i ndli ch er Unterri cht von H li t tenwerken, Meyer , B runswi ck , 1 8
73 ,
I IO .
4 ME TALLURGY OF LE AD

i f i t ha d, the text of Barba i s so unmetallurgi cal that hi s advocacy coul d

amount to li ttle if any thi ng .

T he separati on of lea d and si lver i s accompli shed mai nl y by cupelli ng .

I t does not seem reaso nable to suppo se th at the silver i n the ear li e st ti mes w as

obtai ne d exclusi vely from ores contai ni ng nati ve silver ; the supposi ti on that at
least a large p art w as ex tr acted from argenti ferous gal e na i s li keli e r and thi s ,

requi res cupellati on The earli est actual reference to thi s process i s probably
1
.

that fou nd i n the hymn to Gi bi l (p another i s the one i n Jerem i ah .

,

VI 2 9 30 who li ved about 600 B C ; the remai ns of Lau ri um Show that cu

, , ,
. .

pellati on was i n Operati on there Silver was abundant i n Babyloni a about .

4 000 B C ; th i s le
.a d.s to t he beli ef th a t cupe llati o n had i ts o ri gi n there T h e .

silver vase of E ntem ena 2 800 B C 2 8 i n h i gh beautiq y wroug h t sta nd i

, ng . .
,
.
, ,

on a copper base 7 i n hi gh sho w

”
s the metallurgi cal sk i ll of the B aby lo ni ans at
.

thi s early da te .

2 S tati sti cs — The worl d s pro ducti o n of lead i n 1 9 1 3 i s gi ven i n Table 1

’
.
,

that Of the Uni ted S tates i n 1 9 1 6 i n Table 2 .

T ABLE 1 .
-
W ORLD ’
S PR ODU CTI O N or LE AD IN 1 9 3
1 '

( In metri c tons)

Japan
Mexi co
Russi a
Sp a m
Swed en

Uni ted Ki ngdo m

Uni ted States

Table hows that the Uni ted States produced 34 per cent of the wo rld s
1 s .
’

lead Of th e di fi erent states gi ven i n Table 2 Mi ssour i ranks first i n the output
.
,

of lead ores and these are non argenti ferous I t i s followed by I daho w here i s
,
-
.

mi ned silver bear ing galena ; next come Utah and Colorado wi th lead ores con
-

tai ni ng sil ver These four states fur ni sh nearly 90 per ce nt of the co untry s
. .
’

lead I n addi ti on to the pri mary lead pro duced from nati ve and forei gn ores
.

the re has to be consi dered a consi derable amount of secondary or junk lead ‘
,

that i s lead and lead alloys recovered from scrap junk and dro sses whi ch equals
, , , ,

from 1 0 to 1 5 per cent of the pri mary lead produced from ores . .

Besi de m etac lead there i s produced di rect from ore a product kno w n as
sub li med le ad a mi xture of sul ph ate and Oxi de of lead
,
.

l
B enner Hartmann “E arl
y Hi s tory of Cup ell at i on Mi n , . S e Press, 1 9 1 2 , CW , 501
. .

3 Handcock ,
P S P,
. . . Mes0potami an Arch e ology ,
”
Putna m , N ew Y ork ,
1 9 1 2 , p 2 65 . .

‘
M i neral I nd ustry 1 9 1 6 xxv 4 56 , , ,
.

Li ddell E ng M i n J 1 9 1 2 x c 4 52
, . . .
, , , .

Dunlap , Mi n Res U S 1 9 1 4 I 1 7 2 5—. . . .

.
, , ,
 I N TROD UCTI ON

TABLE 2 -
UNrrED STATE S
’
PRODUCTI ON or PRD LARY LE AD IN 1 91 6
1

( In short tons, ap porti oned accordi ng to source of ore )

D omes ti c ore D omesti c ore

Total fro mdomesti c o e r . .

59 6, 2 2 1
Forei gn ore :

Canada O O O O O O O O O O O O O O O O O O O

Central A mi er ca

Mexi co .

South A mri e ca

Oth er forei gn
Foreign lead bulli on
Canada
Mexi co
South Ameri ca

T otal from foreign ore

and l ead bulli on

Grand total fromall sources 61 27

T here are s ol d in the market three grades of pri mary metalli c lead : De
veriz e d
sil ,
s oft , and anti mo ni al lead The stati sti cs for 1 9 1 6 are gi ven i n
.
3

Table 3 .

TABLE 3 .
— GRADE S or PRD IARY LE AD or TH E UN ITE D STATES IN 1 9 1 6

( I n sh ort t o ns)

D omesti c des i lverized lead

D omesti c soft lead

Forei gn desi lverized lead .

Total p roducti on of refined p ri mary lead

of desi lveri zed lead i n N ewYork i n 1 9 1 6 was

The aver age pri ce cts p er .

pou nd ; that of soft lead whi ch comes from non arge ntiferous ore bri ngs from -

5 t o 1 0 ct s per 1 00 lb le ss
. t h an doe s th e de silve ri z ed ; the pri ce of ant i mo ni al
.

lead vari es wi th th e amou nt of anti mo ny whi ch r anges from 1 5 to 30 per ce nt .

,

averagi ng 1 6 p er ce nt .

In 1 9 1 4 w i th an average pri ce of
,
cts p er pou nd i n N ewYork t he .
,

total co st of pro ducti on co uld not exceed cts per pou nd if i t w as to p ay .

expenses “ .

1
U S
. . Geol . Survey, 191 7 .

1
U S Geol Survey, 1 9 1 7
m
. . . .

1 I ngalls, E ng . Mi n . J .
,
1 9 1 4 , x cv ,
1 0 73 .
6 ME TALLURG Y OF LE AD

The uses of lead many The metal i s used i n the form of sheet and pi pe are . .

Di fierent pi eces are joi ned by burni ng and solderi ng

1 1
O ther forms of metalli c .

lea d u se d mainl y for calki ng are lea d wool powdery lead and ri bbo n lead
,
1 ‘ ‘
, , , .

Granula ted lead is used for assay p urpo ses Lead forms a part of i mportant .

all oys and serves for maki ng whi te lead li tharge red lead orange mi neral etc
, , , , ,
.

B i bli o r h — T h le di ng m n u l n n n fe o u met ll urgy o ntai n

3 g p y
a e a a a s o o rr s a c -
. .

val uable chapters on the metall urgy of lea d and lea d silver as e g those -

, ,
. .
,

of Stii lzel Kerl Balli ng Philli ps Bauerm ann -

Schnabel Loui s Hil debrandt-

Borchers H all H ayward - -

Sexton Pri mro se -

Prost Austi n Wysor and

Gowland
The follo w i ng are the pri nci pal publi cati ons deali ng wi th lead and lead

CAH E N , M . La métallu gi r e du p lo mb , Ree Uni v . . Mi n .

, 1 863, m , 1 , 1 61 ; repri nt Noblet
Baudry, Pari s Li ege, -
1 863 .

GRUNE R , L .
“Sur l ’etat actuel de la metall u gi e du plomb r , Ann . Mi ra , 1 868, 11111, 3 2 5 ; 1 869 ,

xv, 5 9;
1 rep ri nts Dunod ,
Paris .

PE RCY, J
“Metallurgy of Lead, Murray, London, 1 870
.
”
.

RIVOT , L E “Trai té de Mé tall urgi e, D unod, Pari s, 1 873, Vol

.
”
. . 11 .

M Metallurgy of Argenti ferous Lead Crosby, Lock w

”
EI S SLE R, .
, ood Son, London, 1 89 1 .

LAMB E RT, TII .

“Lead and I ts Co mpound s,
”
Scott , Greenwood 81 Cc .
,
London, 1 90 2 .

M W
I LE S , . . Lead S melti ng W il y N wYork 90 ,
”
e , e , 1 2.

g i th Som Notes on Lead Mi ni ng

I N GALLS W R
“L ad Sml ti n and R fini n w e e McGraw
,
. .
g e e ,

Hi ll Book Co I nc N ewYork 1 906 .

, .
, , .

H IX O N H W ,
Notes on Lead and Cop per Smelti ng and Cop p er Converti ng McGrawHill
. .
,
-

Book Co I nc N ewYork 1 908 .

, .
, , .

COLLI N S H F
“Metallurgy of Load Grifi n London; Li p p i ncot t Phi ladelp h ia 1 9 1 0
, . .
, , , , .

the works quoted that of Percy whi le old retai ns a permanent i nteres t
Of , , ,

on accou nt of the chapters on the fire ch emi stry of lea d ; the o nly modern work -

whi ch ai ms at complete ness i s that of Collins .

1
Rothwell, Mi n . I nd .
, 1 89 5, IV, 73 5 .

“
Lunge, G , S ulp h uri c Aci d and AlkalI , Gurney London
.
, , 1 903, I , 4 33 and foil .

“
Fay, C H , The Art of Lead B urni ng, . . D W ill i ams Co
. .
, N ewYork , . 1 90 5 .

Schoop , Mcl . Che m E ng . .

,
1 90 5, In , 2 00 .

Li gh tfoot, op ci t , 1 908, v1 , 1 2 . .

1 “
Ri ch ter, C , Das L6 then des Blei es, Hartleben, Lei p si c, Vi enna, 1 896
. .

1
Edi tor, E ng Mi n J , 1 906, Lxxxn , 59 2 . . . .

Rei ni ck er, Gas Age, 1 9 1 5, xxx v, 3 2 5 .

Bai ley, U S Patent, N o 84 63 84 , March 5, 1 90 7, and No 86444 3, August

. . . . 2 7, 1 90 7 .

1 Edi tor B r s
, as World, 1 9 1 0, VI , 1 73 .
8 M E TALLURGY OF LE AD

th at an allotropi c change i s the cause of the occasi onal breaki ng up of lea d

sheets i nto separ ate cry stals especi ally wh en i n the p rese nce of an electrolyte
, .

J ii ne ck e
‘
no ti ced a tr ansfo rma ti o n at 60 C °
.

Lead i s e speci ally soft when allowed to cool and soli di fy Slow ly ; i t i s less
soft whe n coo le d q ui ckl y and be come s hard whe n i t co ntai ns S li ght adm
, i x tures
of other metals such as Cu As Sb Zn etc The gr ade of commer ci al lead i s
, , , , ,
.

often approxi mately determi ned by the resi stance i t offers to scratchi ng wi th
the finger nail and the facili ty wi th whi ch i t makes a gray streak on paper
,
.

T he te nsi l e stre ngth i s low 2 600 3300 lb per squ are i nch ; the e lasti c li m i t
—
,
.

lb T he compressi ve stre ngth i s about

. ti mes the tenaci ty .

FIG . 2 .
-

Cast lead, reduced, octahedral forms .

very malleable bei ng readily ro lled i nto sheets and hammered i nto foi l
It is ,
.

Anneali ng begi ns to show i ts efi ect at 70 C 1

and i ncreases wi t h ri se of tem
°
.
,

p e rat ure to 2 50 —
2 80 C A t 1 00 C
° 8
cry st
°
al li z a ti o n.o cc u rs to a m arke d degree °
.

i n a sho rt ti me Recrystalli zati o n of cold wo rked lead at ordi nary temperatu re

.
-

takes place very slowly ‘

Fi gs 3 and 4 by C ampbell rep resent unannealed
.
15
.

st ri s of lead ro lled from small i ngots cast i n i ro n and sto ne mol ds ; they have
p
1
. m
Z t phys Che , 1 9 1 5, x c, 2 57, 3 1 3
. .

1 Robi n, Rev Met , 1 9 1 3, x , 72 2 , 788

. .

1 Ew en Rosenhai n, P hi l Trans Roy S oc ,

-
. . . . 1 900 , cx cv, A, 2 79 . Beilby, J . I us t M et ,
1 91 1 ,

VI , 2 .

Baucke, I nternet Zt Metallogn , 1 9 1 2 , II , 2 4 3 .

1 Loc ci t .
 PROPE RTI E S OF LE AD 9

a fine stru cture Fi gs 5 and 6 are photomi cro graphs of the same stri ps annealed
. .

°
for 7 days at about 1 80 C ; the rearrangement and growth of crystals or gr ai ns
.

are we ll show n Fi g 7 show s a pi ece of sheet lead several years old the
. .
,

s mall cry stals have b ee n forme d i n th e strai ned metal by the growth of gr ai n
°
at o rdi nary temper ature T he same S heet annealed for 7 days at 1 80 C Fi g . .
,
.

8 sh ows the remark able growth of crystals taki ng place at a hi gher tem
,

p era t ure Lea d i s

. n o t su fi ci ently du ct ile to be dr awn i nto fine wi re .

The fracture of le ad i s hackly whe n broke n cold columnar w he n hot , .

I n the form of fili ngs i t becomes a soli d m ass if subjected to a p ressure of

1 3 to ns p er squ are i nch and li quefies under 33 to ns
1
.

FI GS .
3 and 4
— Roll e
.d lead, una nneal ed . FI GS 5 and 6
.
— Sa . me l ead, anneal ed.

u h as O 502 H N C0 C03 C H , are i nsoluble i n soli d and li qui d

Gas es 1
s c , , , , , , , ,

lea d ; the gase s 0 and SO, m ay combi ne wi th i t under sui tab le co ndi ti o ns but ,

th e o the rs do not .

° °
The melti ng poi nt of lead i s C ; at from 3 to 1 0 below i ts me lt i ng
3
.

poi nt i t becomes very bri ttle 4

I ts vi scosi ty has bee n dete rmi ne d by Pri i ss ‘
. .

The bo ili ng poi nt at 760 mm i s 1 52 5 C “ KahlbaumRoth Si e dler dis "

.
°
.
- -

1
Sp ri ng, Ann Chi P hys , 1 88 1 , xxn ,
. m. . 1 70 ; B ull S oc Chi nt . .
, 1 883, X L, 520 .

1
Stahl, Che m
Z , 1 9 1 6, xxx rx , 885
. . .

1 Bureau of Standards, B ull 3 5, 1 9 1 5

m
. .

1
Ew en Rosenh ai n, J
-
I nst Met , 1 9 1 2 , v .
,
2 ; 1 91 3, x , 1 1 9.
1
Zt Che , 1 9 1 5, x cIII , 1
ouarg . m .

1 Greenwood, Tr Faraday S oc , 1 9 1 1 , . . VD , 1 45 .

7
Zt anorg . Chant , 1 90 2 , xx nt , 2 78 .
10 ME TALLURGY OF LEAD

tilled lead obtai ned small globules wi th adhering

and M oi s —
cubo octahe dro ns ;

S an W atanabe di stilled alloys of Ag Cu Ag Sn and Ag Pb and fo und th a t

-
l - - -

, , ,

these four meta ls can be arranged as to volati li ty i n the followi ng order : Pb ,

Ag Cu Sn M olte n lead does not gi ve 03 any vapor at 500 52 0 C ; so me

— 1 ° °
. .
, ,

vapor m — p e e e of ot r met e p y ° °
ay be noti ced at 850 900 C ; th e r s nc h e als s e c i all .
,

Zn and Sb reduces the temperat ure at whi ch vapor forms

,
The calculati o ns of .

Ri chards show that lead is volati le to a small ex te nt at a lowred hea t ( 62 5

1 °

FIG .
7.
— Sheet lead
,
several years old . FI G . 8 — Sa
. me lead ,
annealed .

°
Th e of
di lata ti o n of soli d lead for 1 C i s 0 2 9 2 4 X
coefi ci ent linear at . .

°
at 3 2 0 C ; th at of the cub i cal dil a tati o n of li qui d lead
°
and
1
40 X .

i s I 29 X 1 C
.
1 —
at 3 2 5 3 2 7 C
“
The mean specific heat of soli d lead i s
° °
.

0 000 1 9t ; th e h eat i n mol te n lead at i ts me l ti ng poi nt i s cal ; the late nt

1
. .

heat of fu si on cal ; the hea t i n just mel ted lead

, cal ; the speci fic hea t
.
,
.

i n li qui d lea d the late nt h eat of vapo ri zati o n 2 30 Cal p er ki logram ; the .

speci fi c gr av i ty of the vapor ( r efe r red to H a t th e sa me te mpe ra tu re an d

pressu re) or g p er cm at 0 C and 760 mm p ressure The conducti vi ty
,
1
. .
°
. . .

for he at k i n g cal per cm per deg C h .1

.
M-
I l a t ) 1s . for 0 C . . .
,
- -
°
.
,
°
and for 1 00 C ; or wi th Ag 1 00 that of Pb at 1 2 C is .
,
.

The specific r esi stance i n ohms at 0 C of a wi re 1 cm long and 1 sq cmi n

°
. . . .

secti o n i s 1 9 1 4 X 1 0
1
th t of w i e ft lo ng n d i
5 000 i n i n di meter i
‘

; a a . r 1 a a s . .

—1 °
X 1 0 ; the per ce ntage i ncrease of resi s tance for 1 C i ncrease of tempera .

°
ture at 2 0 i s
1
Co pt m rend .
, 1 90 7, cx u v, 16 .

1
Lewi n, Metall . u E ra ,. 1 9 1 3, x , 44 1 .

1 “Metallur i cal Calculati ons ” McGrawHi ll Book Co I nc NewYork , 8, p t 3, 558

g 1 99
-
.
, .
, , . .

1
Fi zeau, Pogg A t , 1 869 , cxxxv . m m , 26 .

1 Vi centi ni O odei , Ani di Tori no,

-
m 1 88 7 -

88, xx m 38,
.

1
Ri ch ards, loc . ci t , 557 .

“S tandard Handbook of Electri cal E ngi neers McGrawHill Book Co

3d Edi ti on, Inc ,
7 -

, .
, .

NewYork , 1 908, pp . 1 3 1 and 1 34 .

 PROPE RTI E S OF LE AD ll

5 C h e. i cal m i c wei ght i s 2 07 1 Lea d und ergoe

Properti es
s no — The ato m
change i n perfectly dry ai r If mel ted i n contact wi th ai r i t i s oxi di zed and .

becomes covered w i th an i Ii descent pelli cle Sai d to be s O ; th i s slowly changes

°
i nto Pho hea ted to from 300 to 500 C for sufi ci ent ti me PhO i s conve rted
. If .

°
i nto Pb304 whi ch i s di ssoci ated i nto 3Pho and O at 550 C
,
1
All oxi des wi th .

mo re 0 than PhO are completely decomposed into PM and O at 630 C °

.

Lead i s no t attacked by w a ter tha t i s fr ee from ai r; i ts surface be comes dull

1

by oxi da ti on when i n contact wi th w ater that i s not free from ai r or wi th atmo s ,

p heri c ai r on a cco unt of th e w a t er wh i c h thi s co n ta i n s Th e co rro s i o n of lea d .

servi ce p i pe-
s
3
i s the greater the sof ter the w a te r; the pres ence of O hastens i t ,

tha t of CO , does the same up to a certai n poi nt and then retards i t on account of ,

the coati ng of basi c carbonate formed ; ni trates am moni um sal ts and calci um , ,

and al umi num sulph ates assist i t .

The bes t solvent of lead i s H N O g; dilute H Cl and H 3$ O 4 have li ttle or no

°
acti on; boi li ng H Cl and H , SO , of 66 Ré di ssolve i t slowly The resear ches of . .

Lunge and Sch mi d on the acti on of H 3SO , and H N O a on lead of di fierent

1 1

degrees of p uri ty gave i mportant res ults The followi ng are the pri nci pal facts : .

The purer the lea d the less will i t be attacked by pure or ni trous sulphuri c aci d
°
up to 2 00 C the hi ghest temperature employed under normal condi ti ons i n con
.
,
° °
centrati ng pans ; above 2 00 C the acti o n becomes stronger and at 2 60 C lead . .

i s sudde nl y di ssolved completely S and SO , bei ng formed Thi s sudden , .

efiect of the aci d can be sli gh tly retarded by the addi ti on of 1 per ce nt Sb and .

prevented by the addi ti on of p e r ce n t C u to the le ad Co n ce n tr at ed n i trou s . .

sul phuri c aci d acts at al l temperature s more p ow erq y th a n pure su lphu ri c

aci d and the efi ect i s gr eater i n the prese nce of ai r

,
Dilute ni trous sulphuri c .

aci d of a sp gr of to i s not as powerful as the pure aci d al though i f

. .
,

the di l u ti on be conti nued beyond thi s point the power i ncrease s agai n instead of

1
Millbauer Chem Z ,
. .
,
1 908, xxx m5 , 1 3, 52 2 ; 1 9 1 2 , xxxvr, 1 4 36, 1 4 84 .

Rei nders Hamburger Zt Ghent

m
-

, anorg. , 1 9 1 4 , 1211111 121, 71 .

1
La m bert Cu -
s, Tr Che . mS .
5, CVII , 2 1 0
oc , 1 9 1
. .

1 Wolfih ilgel , Arbei ten Kai s

'

. Gesundhei tsa t, 1 904 , m 11 , 112

mfllle Hei e Auerbach p ci t 906 xxm 333 (Zt El

.

Paul O hl -
r -
s -

, o .
, 1 , , ectroche m 1 906 , xn ,

Pr c Chem S c
.
,

Clowe s 9, X VIII 4 6 o . . o .
, 1 02, ,
.

Fordo C m pt r nd 8 7
s,
3 Lxx vn 099 86 ;
o 874 D own e .
, 1 , ,
1 , 1 1 1 , ,
1 1 08, 1 401 .

Clark , “M ass Board of Heal th Rep ort ” —

1 89 8, 54 1 585 ;
.
,
1 900, 4 87 .

Heyn , Versuche ti ber das Verhalten von Kup fer Zi nk , , und Blei gegenii berZe ment , Beton,

und den da mi t i n B ruhrung st e ehenden Fltlssi gk ei ten,

”
E rnst and Kom, Berli n, 1 9 1 1 , 59 pages
( Abstr AmChemS oc
.

Scala, M omac ad Li ncei . c .

, V111 , 576 . . . .
,
1 91 2, v1 , 1 9 1 3,

xxn , 1 55 ( Abstr J I nst Met . .

,
1 9 1 3, x ,

Vaubl, Z t ange w Chem

. .
, 1 9 1 2 , xxv, 2 300 .

Gai nes , J .I nd E ng Che . . m .

,
1 9 1 3, v , 766 .

H eap , J . S oc Che I nd . m . .
, 1 9 1 3 , xxxn, 81 1 , 84 7
77 ,
1 .

m
La bert Culli s, Proc Che -
. mS oc . .
,
1 9 1 4 , xxx , 1 98 ; J Che . mS . oc , 1 9 1
.
5, CVII , 2 1 0 .

1
E ng . Mi n J . 893, W , 8, 3 2 , 56
1 .

1
Uber di e w
Ei n i ck ung von rei ner, ni troser und rauchender Schw efelsaure und Salp eter

si ure auf rei nes Blei und Legi rungen von Blei mi t Anti m on und Kup fer,
”
Ri chne, BAR, 1 89 2 ;
Zt anorg . Chant , 1 89 2 , 11 , 4 51 , 64 2 .
12 ME TALLURGY OF LE AD

di mi ni shi ng Junge fo und that in the m

. a tter of corro si on by ni trous sulphuri c
1

aci d smoo th ne ss or a rough ne ss of su rf ace made more di fierence than a sli gh t

,

vari ati on i n the ch emi cal compo si ti on the rough surf ace bei ng the mo re readily ,

atta cke d .

Sanderson combats the i dea that Sb and Cu have a retardi ng efi ect upo n
1

the di ssoluti on of lead hi s experi ments i n two sulphur i c aci d p lants havi ng
,

Shown th at even small admi xtures of Sb and Cu weakened the lead and that ,

the co rrosi on i ncreased wi th the temperature and the percentage of intermi xed
alloy .

°
Lead i s attacked by S0. between 550 and 850 C i n accordance w i th the .

eq u ati o n I t i s also acted Upon by H F but the di s ,

solvi ng power i s qu i ckly ch ecked by the fo rmati o n of Pn ; hence the aci d can

be stored i n lead ves sels ’

Organi c aci ds a ceti c tarta ri c and ci tr i c aci ds
— .
, ,

at tack lead i n co ntact w i th ai r .

1
Frei berg, J ahrb , . 1 89 5, 11 ; B erg H ial en
. mZ . 1 89 6, W , 33 .

1
E ng Mi n J 1 903 , LXX VI , 767
m
. . . .
,

1 Jager , Zt anorg . Che m .

,
1 90 1 , 1, 2 2 .
 CH AP TE R I II

LEAD OF COMM ERCE , ITS IMPURITIES AND TH EIR EFFECTS

6 Grades of Lead
. Th e pri mary lead produced by smel teri es i s very
.
-

pure ,

contai ni ng over 99 per cent Pb Of th e three grade s on the market . . th e

des i lveri z ed co ntai ns the smallest amount of i mpuri ty ; next foll ows the un
desi lve ri z ed ; anti mo ni al lead form s a class by i tself .

I mpure lead bulli on whi ch i s to be freed fro m preci ous metals ei ther
by th e P arkes 3 )
1 or th e B etts p roce s s be come s p uri fied to su ch a ,

de gree th at the market lea d retai ns u sually no t more than per cent .

i mpuri ty Re fined lead resul ti ng from desilveri z ati on by th e P atti nson

.

process i s not sold i n the Uni ted S tate s although th e p ro ce ss i s i n

use i n one i nstance as an auxili ary to the P arke s for the removal of Bi .

Undesi l veri zed lead or soft lead comes from th e non argenti ferous ore of the -

Mi ssissi ppi Vall ey I t i s less pure than the desilveriz e d but i s of hi gh grade
.
, ,

as i t i s smelte d from ore s co ntai ni ng few i mpuri ti e s The lower th e temperature .

at whi ch the lea d i s p ro du ce d th e le ss wi ll the i mpu ri ti e s ente r the lead ; h e nce

,

lead from the ore hearth wi ll be p urer than that from the reverberatory furnace
-

and th at f rom the b last furnace wi ll be the leas t pu re All th e soft le ad i s .

li q uated and th en poled at a temperature a li ttle above the melti ng poi nt i n

order to remove i mpuri ti es Some smel ti ng plants desilverize the soft lead by
.

means of the Parkes process i n order to i mp rove the characte r of th e

me tal as the sma ll amount of si l ve r recovered and th e hi gher pri ce obtai ned for
,

the lea d make the p rocedure profi table .

Anti mo ni al lead i s a by product of the P arkes process ; i t contai ns -

from 1 5 to 30 p er cent Sb Usually there i s present a considerable amount

. .

of Cu .

D esilveri zed and soft leads are u sed mai nly i n the manufacture of whi te lead ,

of sheet pi pe shot and alloys ; some mi nor uses are the preparati on of lead
, , ,

wool powdery lead ri bbon lead and assay lead Th ey serve fu rther for the
, , ,
.

produ cti on of li tharge red lead o range m ineral and lead salts Anti moni al
, , ,
.

lea d i s used for mak i ng type metal beari ng metal and othe r i ndustri al alloys , ,
.

T h e amou nts of lead ab so rbe d at p re sent by the di fi erent i ndu stri e s i s not
kno w n An older statement by C aswell i s th e followi ng : P ai nt ( wh i te lead
.
1
,

li tha rge etc ) 3 5 p er cent ; lead p i pe 2 0 ; sheet lead 8 ; Shot and bull et s 9 ;
,
. .
, , ,

so lder 5 ; tamp i ng filli ng knob s tri mmi ng s etc

, ,
2 3 p er ce nt , ,
.
,
.

Table 4 contai ns chemi cal analyses of some of the pri nci p al Ameri can b rands
of lead Some well k nown E uropean makes have bee n added for the sake
.
-

of co mp ari son .

1 I ron Age, 1 89 6, m9
m , .
14 ME TALLURGY OF LE AD

TAB LE 4
— C11E 1II CAL AN ALYS E S OP CO
. MM E RCIAL LE AD 1

J o pl i n G ranby. St J oseph
MO .
.

MO .
.

MO .
.
H arz M ountai ns

Bl ast Ore
fu nace
r h eart h

0 0 1 50
0 002 3
Trace T race Trace 0 0006
0 0 0 0
i e e e a e a e 0 0008 8
0

T race T race
0 0 1 00
0 002 8 1 0 00 1 0
01 600 0 0° 1
. 8 None

Trace

I nsol .

Pb. by di ff .

Re f erence . Tr A I . . . Tr A I
. . Pri vate Z t Ben B atten Pri vate
M E . M . E not es .
J une . 191 5 . 5 01 W ar i P r
. . . . . notes.
1 8 8 —
9 9 0. 1 8 76 7 7 . -
1 8 70. x V1 1 1 . 2 05 .

XVIII .
687 .

Bal bach Usi ne

A S
S . R Interna t i onal Port H o bo
11“
.

31 2 5, 3
1 11 °
00 Lead Co . . Pi ri e .

Newar k . E ast C i cago h N S W

. . . Anvera .

N J . . B elg i u m

Par k es Par k es

No ne No ne

0 001 0

N o ne t ra ce

N o ne

0 0008
0 00 1 0

None
Se. Te
no ne
Pb. by di fi .
99 9 9 3 8

Re f erence . H . H . Alexander J une. . E Ran

. G P H ulst .
. . M i neral Ann .

1 9 1 5. ( 1019 11 , J une. 1 9 1 5. I nd ustry, Mi n .

J une. 1 9 07 . B elg
1915 . xvr. 6 58 . 1 90 1 ,

VI . 2 59 .

1 Collect i on of Anal yses : G meli n Kraut-

. H and buc h der An org ani ech en Ch emi e. W inter Hei delberg
. .

1 2 . IV. pt46 . 2. .

M i neral I nd ustry. 1 004 . 11 1 1 1 . 2 7 5 ; 1 9 05 . E N . . 65 8

3 8 8 ; 1 9 07 . xvr .
16 ME TALL URGY OF LE AD

Thu s i t i s beari ng lead cooled down slowly wi ll al ways re tai n

s en e that Cu -

a li t tle Cu E arli er i nvesti gati ons of Rei ch had shown that i n li qua ti ng
1
.
, ,

Cu bearing lead retained as a mi ni mum

-
per ce nt Cu whi le the resi d ua l . .

coppery dross formed a bri ttle po rous mass The st eeply ri si ng branch of .

the curve Pb 65 per cent Cu ( Fi g 9) Sh ow s how th e so lub ili ty of Cu i n P b

. .

i ncreases wi th the temp er ature and thereby howi mportant i t i s to k eep lowth e ,

temperature i n melti ng coppery lead i f the Cu i s to be concentrated i n th e ,

dross coll ecti ng on the surface In order to remove thi s remai ni ng Cu from Pb .

an ad di ti on of Zn ( P arke s process 52 3 1 ) i s necessary whi ch wi ll extract th e ,

Cu to the practi cal li m i t .

Th e pe rcentage of c0pp er pre sent i n co mmerci al le ad does not i nte rfere w i th

the rolli ng and other mechani cal processe s Accordi ng to Lunge and Sch mi d 1
.
,

lead wi th p er ce n t Cu show s th e sa me be h a v i or
. a s pu r e l e a d w i th c o l d
° °
sulph ur i c aci d ; so doe s lead wi th per cent Cu up to 1 00 C At 2 00 C . . .

lead wi th from to p e r ce n t Cu i s al mo s t a s mu ch a tt a c ke d a s pur e .

lead i s and more than i t i s by ni trous sulph u ri c aci d

, Ju nge says that i n
’
.

co ncentr at i ng p ans P arkes lead has been observed to be mo re readily attacke d

,

than P atti nson lead and he attri butes thi s to the fact that the re i s less coppe r
,

i n the P arke s lead wh i ch maki ng the mel ti ng poi nt lower i ncrease s the li ab i li ty
, ,

of be i ng attacked by the aci d If u sed for corrodi ng or for maki ng fli nt glass .

-

the per centage of Cu ough t no t to exceed

1
0 90 80 1 623 f ” 20 m0
0
7
1 per cent A cco rd i ng to Ju nge the
. 1
10
.

1111 As lowest perm i ssi ble amount i s p e r ce nt .

i
Si lv er — T h ll oy er i e P b —
A h
9 e a s s g a s . .

bee n studi ed by H eycock N evi lle Fri edri ch 1 “ -

and Pe tre nk o
7
The V Shaped cu rve of .
-

Fri edr i ch gi ven i n Fi g 1 1 S hows the e xi st ,

.
,

e nce of an eutecti c wi th 2 5 per cent Ag . .

,
°
freezi ng at 300 C and the ex tensi o n of the .
,

1° 11° 1 ° 1° 1 ° 7° 9° 9°
3
3or C nt Ao eute cti c
o
li ne to t h e o rd i na te s ; t h i s me a n s th a t
.

no Soll d solutl ons are fo rmed between Pb In

FIG 1 1 . Alloy seri es Pb Ag
.
,
-
.

Ag and Ag i n Pb The small amounts of ,

.

Ag prese nt i n market lead i oz per ton are therefo re due to eutecti c ,

.
,

di ssem i nated th rough the lead ; th i s fact explai ns i n part the i rregular di stri
buti on of Ag i n le ad bulli on
What has been sai d about the efi ect of Cu i n regard to the mechani cal treat
ment of lead holds good for Ag S mall quanti ti es of Ag protect lead agai nst .

sulphur i c aci d Baker says th at oz of Ag per ton gi v es whi te lead a

11
. .

1
Frei berg J ahrb , . . 1 860, 1 86 .
1
Loc . ci t
1
Loc . ci t
1 Hampe Z t B erg Ril lton S al Wes i Pr 1 8 70, W 111 , 209 .

m
. .
, , . . . .

1 Phil Trans , 1 89 7, c , 37 .

m
. .

1 M elall nrgi e, 1 906, , 398

m
.

1
Zt Che , 1 90 7, L
anorg m 20 2

0m m 1
.
. .
,

1 Di ngl Polytech J , 1 864,

. . . . 1 9.
 LE AD OF COM M E RCE 17

reddi sh tinge but thi s i s not the case w i th oz p er ton

,
Landsberg gi ves . .
1

as mi ni mum oz for corrodi ng lead ; Junge oz .

, .

1 0 Copper and S i lver

.
— Th e i nve sti gati on of Fri edri ch and Leroux has
1
.

shown that th e alloy seri es Pb Cu Ag fo rm s a ternary eutecti c w

— i th Pb -

° °
Cu 0 5 Ag . per cent whi ch freezes at from 0 5 to 1 C below th e b i nary
,
.
,
. .

—
eutecti c of Pb Ag .

11 Gold — Whil e Au i s not found i n market lead i t occurs i n lead bulli on

. .
, .

Its behavi or i n certai n proces ses for example that of P atti nso n i s readily ex , ,

plai ned by the consti tuti onal di agram tr aced by Vogel gi ven i n Fi g 1 2 Thi s
1
. .

shows the ab se nce of soli d so luti o ns th e prese nce of two chemi cal compounds , ,

Aus and Aus and that of an eutecti c co nsi sti ng of Al l g and Pb wi th , , ,

about 85 p er cent Pb freezi ng at 2 1 5 C and u ndergoi ng a transformati on at

°
.
,
.
,

so 40 60
Per Cent, Pb

FI G — Allo seri es Pb—Au FIG 13 — Alloy seri es, —

Pb Bi
. 12 .
y , . . . .

211
°
C The si milar i ty of thi s curve wi th that of the al loy
.
—
se ri e s Pb Ag at

the lead end i ndi cates that i n lead smelti ng Au whi ch forms a seri e s of soli d
-

, ,

so l uti ons wi th Ag
1
will follow the Ag unless o ther causes i nterfere wi th thi s ,

tendency
1 2 Bi sm
.

uth
.
— —
The equili bri um di agr am of the Pb Bi alloy ser i es by Kapp
.
15

°
and S tofl el Fi g 1 3 shows an eute cti c wi th 4 4 per cent Pb free zi ng at 1 2 4
'
‘
,
. .
, ,
°
1 25 C and soli d soluti o ns of about 1 0 p er ce nt at ei ther end of the eute cti c
.
, .

li ne Lead i s hardened by
.
5 p
2 er ce nt B i 7
and re ndered somewh at .
,

cry stalli ne Junge rolled wi thout difi cul ty lead contai ni ng 2 per cent B i
. .

i nto a sh eet 1 0 ft long 6 ft w i de and 16 4 i n th i ck ; and Burgraf say s that lead

.
, .
, .

1
Wagner J ahresber , . 1 875, xxx, 59 6 .

”1 10111111 15 1
I 9° 71 N : 2 93 °

1 Zt Ghent , 1 905, v , 1 7
anorg . .

1 Roberts Austen and Rose, Che -

N ews, 1 903 , Lxxxvn , m . 2.

H eycock Nevi lle, Philos Trans , A, 1 89 7, CLxxx nt , 69

-
. . .

1 “D octorate D i ssertati on ” KOni sber 1 0 1

g g, 9
m
, .

1 Zt anorg. Che m 1 90 7, L 150

m
. .
,

Hal lenmZ
,

7 Plattner, Berg . . .
, 1 889, v ,
1 1 6.

3
18 ME TALLURGY OF '
LE AD

wi th per cent Bi can be rolled i nto sheets as well as refined lead p racti .

cally free from b i smuth .

Accordi ng to N ap i er and Bauer‘ 1

per ce nt B i protects lead some , .

°
wha t from sulphu ri c aci d at 2 0 C but not at 1 00 C whi le j u nge e xposed ° ’
1 .
, .
,

stri p s of l ea d wi th e t to u p r d of °
p er c n B i s l h u i c aci 6 0 B é at the tem . .

p era tu re of the s u lphur i c aci d ch amber an d fou n d n o se nsi b le ch ange L u nge .

and Sch mi d sta te th at lead contai ni ng B i i s su dde nl y di sso lved by con

1

centrated su lph ur i c aci d at a temperat u re below 2 60 C

°
and th at an addi ti on .
,

of per cent Cu counteracts thi s to some extent Accordi ng to H ampe . .

,

from to per cent Bi has no efi ect on whi te lead but Junge .

,

says that per cent makes i tself fel t Refine d lead contai ni ng over . .

per cent B 1 i s no longer classed i n thi s country as corrodi ng lead

5
. .

E ndem ann sta te s that b i smu th favo rs the corro si o n of lead a small black ,

res i due remai ni ng co ntai ni ng metalli c b i smuth , .

Th e r eason that the Bi content of corrodi ng lead i s li mi ted i n thi s country -

to per cent a commerci al co mpromi se i s that Bi gi ves whi te lead a grayi sh

.
, ,

color espe ci ally where scrap or u ncorroded bu ckles are reset i n the stack s
,
.

I t has also been fou nd that i t rende rs the uncorroded lead more or less spongy
and granul ar w i th the re sul t that there i s an accumul ati on of thi s materi al i n
,

the grooves of the m illstones and the i r su rfaces are li ke ly to become co ated ,
.

AS lo ng however as the machi nery doe s i ts work prop erly the re i s no danger of
, ,

metalli c part i cle s contami nati ng the pai nt .

There are two ways of removi ng Bi from Pb : one the P atti nso n p rocess ,

whi le i mperfect i s suffici ent for practi cal purposes ; the oth er the Betts , ,

process i s perfect as Bi i s not deposi ted on the cathode but remai ns , ,

undi sso lved i n the anode m ud .

1 3 Cadm. i um Thi s occurs only i n trace s i n market lead

— . The consti tu .

ti onal di agram by Kapp and Stofi el shows an eute cti c wi th about 80 p er cent
6 7
.

Pb freezi ng at 2 4 9 C and on the eutecti c li ne a soli d soluti on of lead wi th about

,
°
.
,

4 per ce n t C d . .

1 4 Ti n.
—1 .
—
Th e consti tuti on of Pb Sn alloys has been the subject of a
number of i nvesti ga ti ons 8
mai nl y on acco unt of the formati ons of soli d solu ,

1
Che m N ew . 880, XI II , 3 1 4 ; S chool M i n Quart , 1 88 5
s, 1 .
—86
,
VII , 9 7 .

1
B er . deutsch che Gesells ch , 1 8 75, ccx , 4 8 ; S chool M i n
. m . . .
Qua rt ,
—
1 88 5 86, VII , 1 1 7 .

1 Op . ci t
1
Op ci t

m4
.

1
Ameri can Che i st, m 1 876, VI , 4 57 ; Wagner J ahresber .
, 1 8 7 7, xx , 2 2.
1
Zt anorg . Ch m e .
,
1 90 7, L111 , 1 52 .

1
Doctorate D i ssertati on ,
K6 nigsberg, 1 9 0 1 .

1
Roberts Austen, E ngi neeri ng, 1 89 7,
-

, 2
23 mm .

Kapp , D octorate D i ssertati on, KOnigsberg, 1 90 1 .

Shep herd, J phys Che . . m 90 2 VI .

,
1 , , 52 2 .

Stofi el, Zt anorg Che . m 1 90 7 L111

.
, , ,
1 39 .

Rosenhai n Tuck er, P hil os Trans A , 1 908, -

. . . 00111 , 89 .

Guertler, Z t Electroche , 1 909 , xv, 1 2 9 m .

D egens , Zt anorg . Ch m e .
, 1 909, a I, 2 1 2 .

Mazzo tto , I nternal Zt . Mel allogr , . 1 9 1 1 , I , 2 89 ; and others.

 LE AD OF COMME RCE 19

ti ons and the transformati ons the alloy s undergo A combinati on of the data .

of Rosenhai n Tucker Degens and Mazzotto i s gi ven i n Fi g 1 4 Thi s shows an

-

, ,
. .

eutecti c wi th p er ce n t Pb fre ez i ng a t 1 8 1 C and a s o li d sol ut i o n at .

°
.

ei th er end of the eu te cti c li ne Pb wi th 1 8 per cent Sn and Sn wi th per ,

.
,
°
’
°
cent Pb There are further seen two transformati ons at 1 61 and 1 4 6 C
. . .

accomp ani ed by ch anges i n the amounts of Pb and Sn hel d i n so li d so luti on .

Ti n makes lead li ght gray and hard I t i s uncommon i n market lea d -

. .
»

Lea d contai ni ng i t i s more afi ected by sulph uri c aci d than pure lead 1
The .

efiect i n corrodi ng has no t been stu di ed I t i s removed by hea ti ng the l e ad .

to a b ri gh t red heat wi th access of ai r; part of th e ti n coll e cti ng on the surface

-

as oxi de i s firs t drawn 011 as a powder and the rest as a slag co nsi s ti ng of ,

I “ c “s»
$ 11 03 or X PbO SnO g di ssolved in Pho
, .

.
10° 8° 1° 1° 90
( S ofte ni ng of Lea d B ulli on I n ,

dustri al alloys are di scussed in § 2 5 .

Per Cent Sb
100 90 80 70 60 60 40 80 20 10 0

0 10 m0 8
Per cent
40 60 60 70 80 90 m
FI G — Alloy seri es, Pb—Sn FIG — Alloy seri es, Pb Sb
I 4. 1 5
-
. . . . .

1 5 Anti ony.
— — m
The consti tuti on of Pb Sb alloy s i s si mple when compared
.

wi th those of Sn I t has been studi ed by H eycock N evi lle , Roland Gosseli n

1
.
1 - -
.

Stead , 1
Charp y, ‘
Campbell , 1
Gonter mann ,
’
and Loche .
s
Fi g .
5
1 by G o nter
mann shows an eutecti c wi th 87 p er cent Pb freezing at 2 4 6 .
,
°
C the eute cti c
.
,

li ne ex tendi ng to the ordi nates 7

’

E ven small quanti ti es of anti mony gi ve lead a grayi sh whi te color and make -

i t harder and less malleab le than ordi nary lead A bar of lea d contai ni ng some .

anti mony w i ll S how especi ally in the center an uneven moss li ke surface , , ,
-
.

H am pe finds that
1
per cent Sb doe s not harden lead ; H eeren sta te s
1°
.

that per cent makes lead hard but that i t i s sti ll m all eable Lead wi th
.
,
.

1
Nap i er ,
B auer, see 5 12 .

1
J . S oc Che . mI nd
. .
, 1 89 2 , L111 , 0
9 4 .

1 Bull S oc d E nconrage
. .
’
menl ,
1 896, I, 30 1 .

1
J S oc Che
. I nd , xvi , 2 00
. m . . .

1 “Contri buti ons 1 l ’ E t ude des Alli a es

g , Cha mrat 81 Ren
e ouard, Paris, 1 90 1 p . 1 31 , 2 1 2
1
J Frankl i n I nst , 1 902 , CLI V, 20 5
. .

1
Z t ouarg Che , 1 907, LV, 4 1 9 . m . .

1 M etall urgi e, 1 9 1 1 , VIII , 7 .

1
Loc . ci t
1°
Percy Ra -
mmel be g s r ,
Di e Metallurgi e des Blei es, Vi eweg , Brunswi ck , 1 8 72 , 4 9 .
20 ME TALLURGY OF LE AD

per cent Sb i s not so eas ily attacked by cold sulphuri c aci d as pure lead
.
,

but more easily by hot aci d Lu nge and Sch m i d sub stanti a te thi s
l
They . .

found that an addi ti on of per cent Sb di d no harm wi th cold sulphuri c aci d .

,

appear i ng r ath er to be be ne fici al ; but lead wi th over p er c e n t S b w a s .

mo re affected than soft lead and the di screpancy i ncreased wi th a hi gher ,

te mperature to an enormous degree .

For corro di ng lea d m ay no t contai n over per cent Sb ( H ampe

, .
,

Landsberg) Junge finds tha t

1
. per cent Sb retards the corrosi on but has .
,

no efi ect on the color of the whi te lead whi le p er ce n t h a s a d ec i ded ly , .

bad i nfluence
Anti mony is removed fro mlead when thi s i s brought to a bri ght red w i th
.

free acce ss of ai r; th e Sb i s oxi diz ed i n part to volati le Sb303 whi ch passe s OE

W i th the gases i n part to stable Sb205 whi ch co m , bi nes wi th PbO formed at the ,

same ti me to form Pb3 ( SbO 4) 2 and i s h eld i n sol u ti o n by the mol te n li tharge
, , .

Industri al alloy s are di scussed i n § 2 4 .

1 6 Arseni c
.
— The lead end of the equi li bri um di agr am has been studi ed by
.
-

Fri edr i ch and H ei ke

1 ‘
The curve of Fri edri ch Fi g 1 6 show s an eutecti c wi th
.
, .
,

P C nt P,
2 5 p
er
er ce nt A s
e
fre ez i n
.
g a t 2 9 2 C ; i n coo l . .
,
°
.

90 so 70 so i ng layeri ng takes place before an ret a d a ti o n

y r ,

i n the cooli ng curve i s noti ced H ei ke carri ed .

on hi s i n ve sti gati ons i n a closed porcelai n tube

hea ted i n an electri c fur nace ; he fo und the
eutecti c to contai n 3 5 per cent As and to freeze . .

°
at 2 80 C ; he note d the absence of soli d solu .

ti ons and chemi cal compounds ; ext rapo lati on of

the curve gave the mel ting po i nt of As as 852 C °
.

The amou nt of As found i n commerci al lea d

10 20 20 40 i s too s m all to h a ve a ny e fi ec t upo n i t s me ch a n

Per C nt A
i cal and chemi cal properti ese .
In refini ng lead
.
.
,
FI G 1 6 — Alloy seri es P —
b As
i t is oxi di zed and slagged as before
.
. .
,

the Sb wi th whi ch i t i s usually associ ated

,
.

Industri al all oys are di scu ssed i n § 2 7

The se occur very rarely i n m
.

1 7 Ni ck el and Cobalt
.
— arket lead The con .

—
sti t uti onal di agram of Pb N i by Voss sh ows nei ther chemi cal compo und nor
‘

eutecti c nor any solubi li ty of N i i n Pb Portevi n however notes an eutecti c

,
‘
.
, ,

wi th per cent Ni freez i ng at 32 3 C The alloys of Pb Cu Ni have been — — °

.
,
.

studi e d by Pat t avano M az zetti

7 -
.

The curve of Pb Co by Lew

— konja shows the presence of an eu tecti c wi th
1

1 Lac . ci t .

1 Loc . ci t .

1 Metalturgi e , 1 906 , 111 , 46 .

1
I nternal Zt Metatlogr , 1 9 1 4, VI , 4 9 ; J . I nst . Met , 1 9 1 4 , x 11 , 2 9 1 .

mm 4 7
. .

1
Zt . anorg . Che m .
, 1 908, ,
.

1
Rev Met 1 90 7, N , 81 3 .

mAb t
.
,

7
Gan . shi m i tch .
,
1 9 1 4 , xu v
’
, 3 75 ; Che . sr .
, 1 9 1 9 , 1x,

1 Zt . anorg . Che m 1 908 , 3 1 4 .

 LE AD OF CO M M E RCE 21

°
b ut 1 p er cent Co freezing at 3 2 6 C and the extensi o n of the eutecti c li ne
a o .
,
.
,

to the ordi nates Bertbi er pro duced a m

l
all ea ble alloy of Pb w
. i th
per ce nt Ni or C0 Mraz ek says that from 1 to 2 per cent Sb favors the
.
1
. .

entrance of N i and Co i nto Pb ; but they r i se to the surface when furnace lead

is m el ted slowly and can be ski mmed ofi easily , .

1 8 Iron —
. The re search of Isaac T am
. mann shows that Pb and Fe have
1 -

no affi ni ty whatever for one another and are ab solutely i m mi sci ble ,
.

Market lead contai ns not more than p er c e n t Fe ‘

an d th i s a mo u n t h as .
,

no effect upo n the mech ani cal properti es Corrodi ng lead ought not to contai n .

more than per cent Fe ‘

. .

1 9 Zi nc —
. The consti tuti on of these alloy s has been studi ed by H eyc0ck
.
~

N eville and Ar ne m
‘
ann and the mutual so lub ili ty of the two metals by Ross
’
,

ler E delmann and Spri ng Rom

- 1
anofi
’
The equi li b ri um di agram Fi g 1 7 -
.
, .
,

sho w s th at th e two metals form one eutecti c wi th ce nt Pb free i n g a t

p er z .
,
° °
3 7
1 C I n the ne.i ghborhoo d of 950 C the y fo rm a homoge n eou s so l ut i on . .

Per Cent. Pb
100 so 00 40 no

so 100

FI G — Allo seri es Pb—Zn

. 1 7 y , .

The saturati on point urve has been traced onl y to 900 C where a separati o n -
c
°
.
,

i nto saturated and unsaturated soluti ons i s noti ced Wi th fall of temperature .

°
the mutual solubili ty decreases to the melti ng poi nt of Z n 4 1 9 C whi ch i s ,
.
,
° °
lowered 1 by the Zn tak i ng up 0 5 p er cent Pb At the temperature of 4 1 8 . . .

there exis t co njugate soluti ons .

Further cooli ng of the mol ten metal does not at first lower the temperature ,

but ca uses an enri ch ment i n Pb until the li qui d contai ns per cent Pb .

or per ce nt Zn; th en o nly does the temperature fall to the eutecti c poi nt
.

°
of 3 1 7 C .

1 “Trai té de
n Essai s par la Voi e Séch e, Th o
”
mm e, Paris, 1 836, n, 69 1 .

1
Berg H atten Z , 1 864 , xx , 3 1 5
. m . . m .

1
Zt anorg Che , 1 90 7, I N , 59
. . m . .

1
Rei ch , Berg Hattc n Z , 1 860, xxx , 2 8, 2 2 4
. m . . .

1
Landsberg, lac oft
m
. .

1
J Che
. m
S oc , 1 89 7, an, 394
. . .

Metallurgi e, 1 9 1 0, vn, 2 01 .

1
Berg H attennz Z , 1 890, xu x , 2 4 5 ; Eng M i n J. . . . .
,
1 890, L, 573 .

1
Zt . anorg . Che m .
,
1 89 7, r
a n, 2 9 .
22 ME TALLURG Y OF LE AD

I n Table 5 by Rossle r E del ann -

m are gi ven the amounts of zi nc that lea d
will retai n at di fi erent temperatures .

TAB LE 5 .
— Sownn rrv . or ZIN C mL E AD

( Rbssler Edel -
mann)
m
Te p erature, deg C . .

Table 6 by Spri ng and Romanofi shows the mutual solu

bi li ty of lea d and

zi nc at di fi erent temperatures .

TABLE 6 .
— MU1 U AL Sowaru rx '
or LE AD AND c

Lo wer stra tu m Up p er stra tu m

d t of
The a a g e Ta ble 6 a r e in a of freez ing poi nt general way wi th those the -

curve but are very mu ch hi gh er th an those of Table 5 ; th e latter have alw

, ay s

served as gui de s to th e re finer .

Zi nc gi ves lead a silvery color and makes i t so hard that i t cannot be rolled ;
col d and hot sulp h ur i c aci d attack i t readi ly Corrodi ng lead should not contai n .

over p e r ce nt (L and sberg ) Z i nc i s. removed from le ad by he a ti ng i t to .

a bri ght red and oxi di zi ng i t by adm i tti ng ai r i ntroduci ng stea m etc
-

, ( See , ,
.

Refini ng D e silveriz ed Lea d § 2 ,

2 0 Manganese
.
— The freezi ng poi nt curve of William s shows that Pb has
1 -

no afii ni ty whateve r for M n and that Mn above i ts mel ti ng poi nt of ,

C .

does hold some lead i n soluti on As regards market lead Mn i s pres ent only .
,

i n very small amounts and has no practi cal i mportance .

2 1 Alum
,

. i num The curve of Gw

—
ye
.r
1
s h ows tha t Pb a nd A l ha ve n o t e

lati ons to one ano ther that Al i s i nsoluble i n Pb and that li qu i d Al m

,
ay di s ,

so lve some Pb Anti mony i s sai d to favor the uni o n of the two me tal s
1 1
. .

1
Zt anorg Chem 1 90 7 w 3 2
. .
, , , .

1
Zt anorg Che m 908, Lvu , 1 4 9
1

m vm
. .

man
. .
,

1
See also Péch eux, m
Co pt rend , 1 904 , c .
,
1 04 2 ; B erg H atten. mZ
. .
,
1 904 , , 34 8 ;
m
Co pt rend , 1 906 , cx u u, 39 7
. .

1 Ri har
c
“
ds, J W , Alu i ni u . . m m ,
”
McGrawHill Book -
Cc .
, Inc , NewYork ,
. 1 89 6, 503 .
 CH APTER I V

23 .
—
GeneraL The alloys i n whi ch lead form s the leadi ng co nsti tuent are not

nu mroue s . They are, however of consi derable i mportance and at the same ti me
,

comparati vely cheap .

The addi ti on of ano ther me tal to lead decreases i ts softnes s and mall eab ili ty .

Thus an addi ti o n of Sb or As i ncreases the hardness and i mpai rs the mallee

,

TAB LE 7 .
— HARDE NIN G E rrscrs or Sour . METALS UPO N LE AD
( Ludwi ck)

Annealed

Added mtal e

Charp y, G Les Alli ages Blancs di ts Anti fri cti on in Contri buti ons 1 l Etude
’
1
.
,

Alli ages, Chal

”
Renouard, Pari s, 1 90 1 m erot -
.

“
Gui llet, L , Les Alli ages Mé talli ques, D unod Pi nat, Paris,
.
” -
1 906 .

B rannt W T “The M etalli c Allo s

”
Bai rd Philadel hi a 1 90 8
, . .
, y , , p , .

“
Krup p , A , Di e Legi rungen, Hartleben, Vi enna , 1 909
”
. .

“
Sexton, A H , Alloys, N on ferrous, Sci entific Publi shi ng Co , Manchester, 1 909
.
”
.
-
. .

Zusam menstellung der Gebrauchli chen Legirungen, Knap p , Kalle,

Kaiser, E W , “ . .
”

—
1 9 1 1 1 2 ; rep ri nt fromMetall urgi e 191 1 V111 , 2 57, 2 96 .

m
, ,

IIi orns, A H , M i xed Metals and Metalli c Alloys , Mac i llan, N ewYork , 1 9 1 2
“
-
”
.
. .

Ledebur, A Bauer, “ ”
Di e Legi rungen, Krayn, Berli n, 1 9 1 3
-

m m
.

Heyn, E Bauer, O , Untersuchungen fiber Lager etalle, Anti on Blei Zi nn Legi rungen,
.
-
.
- -

Bei heft Verh Verei n Beford Gew

. erbe flei ss ,
F ebruar 1 1
y, 9 4 . . .

24
 I N D US TRI AL ALLO YS 25

bili ty; one ofSn also i ncreases the hardnes s, but does not i nterfere
much wi th
the m m
alleabili ty ; Cu has a si i lar efiect al though not to the same
extent but
the tende ncy of Cu to eli quate perm
,

i ts the use of o nl y a small amount ; alloys

— —
of Pb B i and of Pb Cd have bee n prepared but are li ttle used , .

The harde ni ng efiects of Bi Sn Sb Cd Ag and Mg upon Pb have been , , ,

eans of the Br inell m

, ,

stu di ed by Ludwi ck
1
by m ethod ; so me of hi s res ul ts are
gi ven i n Table 7 .

Mg has the grea test hardeni ng efiect on account of the chemi cal compound
Pn : ; the hardeni ng power s of Sb Cd and Ag are si milar ; the all oy w i th 2 , ,

pe r ce n t Sb upo n.an neali ng has i ts h a rdnes s i ncreased to that of o ne w i th 8

per cent . Sb .

The di fi usi on of
the
'
—
alloys Pb Sn — —
Pb Bi , Pb Sb, —
and Pb Sn Sb i s -

s hown by
,

Le Gris i n an excelle nt se ri es of ill ust rati ons

1
.

Table 8 gi ves the com posi ti ons of some of the l eadi ng i ndustri al l ead alloys .

T AB LE 8 — Coup osrrroN 01 Son . I N DU STRI AL LE AD Au ovs

Na m e Pb Sb Sn f
Re erence

Brannt. M etalli c Allors . 36 8 .

B rannt. M etalli c Alloys . 36 8 .

Brannt. M etalli c Alloys . 368 .

B rannt . M etalli c All ys o . 3 68 .

Brannt . M talli c Alloys

e . 3 68 .

W ag ner . Bros: W orld . 1 9 1 4 . x. 83 .

Gui llet , Alli agee M ét alli q ues . 84 5 .

Guillet , Alliagea M étall i q u s e . 84 s .

Gu illet , Alli ages M ét al li q uea . 84 s .

w
Pe ter. Frenc h Guillet . All iagee Metalli q uea . 84 s .

Bu nni e M arAL:
Glaci er. Bros: World 1 9 06 . 1 1 . 132.
mer
.

Cla Brass W orld 1 9 06 . 1 1 . 1 3 2 .

m
. .

Bal t i ore O i o R R t i n li ni ngs h . h Clamer Bros: World 1 9 06, 11 . 1 32

m
.
. . .

B al t i ore O i o R R t i c li ni ngs h . . . h k . Clamer . Bras: W orld 1 9 06 . 1 1 . 1 32.

mer
.

Ch icago E astern R R . . Cla . Brass W orld 1 9 06 . n. 1 32 .

Clam
.

er Brass
. . World 1 906 . 11 . 1 32.
Magno li a metal “
St a nl ey. M etall urgi e. 1 9 06 . 111 . 607.
m m
.

So lder N o 1 A eri can ark et s

Am
. . .

Solder No 2 eri can mark ets .

Am
. .

Sol der No 3 eri can markets

me r
. .

Warr:
-
M enu . on Ann -
t os Bu n

“Bei he t
H eyn B auer.
-
f Verh Verei n . .

B efard . 1 9 1 4. 2 2 5 .

( a) And Cu 2 p er cent .

m
.

Zt anorg Che 1 9 1 6, xcrv, 1 6 1 .

m6 3
. .
.
,

1
Rev . Mi t , 1 91 1 , v , 1 .
26 ME TALLURGY OF LE AD

24 . Lead -
anfi mony
freezi ng po i nt curve Fig 1 5 shows an en
.
— The -

,
.
,
°
tecti c wi th 8 7 p er cent Pb freezi ng at 2 4 6 C ; hence alloy s wi th over 1 3 p er
. .
,

cent Sb consi sti ng of Sb and eutect i c mus t be mo re b ri ttle than tho se wi th

.
, ,

le ss than 1 3 p er cent as these are ma de up of Pb and eutecti c Fi gs 1 8 2 0 rep — .

, .
.

re se nt ph otom i crograph s by Charp y 2 00d

—
of Pb Sb alloys wi th 2 0 40 and ,
.
, , ,

0
7 p er c e nt Sb ; i n all of th em . th e li g h t parts rep rese nt crystals of S b
im be dded i n the dark eutecti c .

—
T h e i ndu stri al Pb Sb alloys contain less than 2 4 per ce nt Sb If a hi gh e r . .

pe rcentage i s to be used a thi rd metal usually Sn has to be added ; i n many , , ,

cases Sn rep laces part of th e Sb .

T ensile bendi ng and comp ressi on tests of Pb Sb alloys have been m ade
, ,
-

by Goo dman upo n three alloys wi th 1 0 1 5 per cent Sb and upo n one wi th
1 — .
,

Fe . 1 8 to 2 0 — . Lead -
anti mony alloys , X 2 00 .

15 p er c n e t . Sb and 5 p er cent Sn Th e tensi on tests show an elasti c li m i t

. .

of about 2 , 000 1b ,
. and a st rength of about lb p er square i nch ; for com .

p ressi on the figures are lb and lb p er square i nch

. Compressi on . .

tests have been made by Charp y ’

.

Th e e xp ansi on curve of E wen T u m e r Fi g 2 1 shows th at wi th addi ti o ns of -

,
.
,

Sb to Pb the e xp ansi on i ncreases to a m axi mum at about 1 3 per cent Sb

, .
,

the eute ct i c compo si t i o n the n falls to m i ni mum at about 3 5 per cent Sb , .

,

ri ses to a se co nd m axi m um at about 50 per ce nt Sb falls agai n to about 60 .

,

p e r ce nt S b and slow ly ri se s to that of pu re Sb

.
, T h e i rregu lari ti es cannot .

be exp lai ned by the freezi ng poi nt curve -

.

The hardness curve of the sam e autho rs Fi g 2 2 gi ven in Shore numbers , .

, ,

sh ows a u ni fo rm r i se i n hard ne ss to th e eute cti c po i nt followe d by a qui cke r ri se

to the m axi mum w i th about 75 p er cent Sb and the n a rap i d fall to pu re Sb .

, .

—
The tendency to li quati o n m akes the sampli ng of Pb Sb alloy s always d ith
cul t
a
An i ndustri al m ethod of approxi mati ng the Sb conte nt of an alloy devi sed
.
-

by Ri chards consi sts in casti ng the alloy to be te sted i nto the form of a
‘
,

1
E ngi neeri ng, 1 906, xxx n , 3 76 .

1
Loc ci t 214 .

mm 4
.

1 N i ssensen Si edler, B erg H atten

-
. mZ . .
,
1 903 , , 21 .

1
J Frankli n I nst ,
. . 1 899 , ca , 39 8 ; I ron Age, 1 899 , 1x 11 , May 1 1 , 12 .
 I N D US TRI AL ALLO YS 27

t d rd siz e p lug i n a speci al mo ld Thi s p lug i s then wei ghed on a speci al

s an a .

balance th e gr adu a ti o ns on the armreadi ng di rectly i n term s of Sb—

, c o ntent
—
of th e alloy si nce the wei ght of the p lug decreases as the Sb co ntent i ncre ase s
, .

Fri edri ch uses anothe r metho d by means of whi ch the freezi ng poi nt of the
1
,

ha rd l ead to be exami ned i s measured wi th sili ca glass thermometer and -

the correspondi ng compo si ti ons read from the melt ing po i nt curve Th e .

method i s te ch ni ca lly accurate for alloys wi th up to 8 per cent Sb ; alloys .

Per Cent Sb
w
.
o
o 10 20 80 40 50 60 70 -
90 1000

100 90 80 70 0
0 50 40 80 20 10 0
Pet Cent J ’ b

Per Cent ,
”
W OO BO TO GO SO 40 30 20 10

10 20 30 40 50 60 70 80 90 100

Fe 21 and 2 2 . — E x ansi on and hardness curves of Pb Sb alloys

p
-
. .

con ai ni n
t g over 8 per cent Sb are di luted wi th a kno wn amount of Pb to
.

fall wi thi n the permi ssi ble range An assay takes about 1 m in . .

Corro si on has been studi ed i n connecti o n wi th type metal M eyer .

Schuster found that corro si on w

1
as less afi ected by chem i cal compo si ti on

than by the manner of casti ng of cleani ng and of stori ng On the other , ,

.

hand Zi nsberg concluded from hi s tests that the lower the Pb content the
,
1 -

greater the resi stance to corrosi on .

1
Metallurgi e ,
1 9 1 2 , 1x , 44 6 .

1
Das M eta”, 1 9 1 4, 1, 35 2 .

1
Loc . ci t .
28 ME TALLURGY OF LE AD

The leadi ng use

of these alloys i s for type metal beari ng metal bullets , ,
1
,

and engravi ng and b attery plates .

Type metal usually co ntai ns some Sn as thi s makes the alloy harder and
m
,

more ri gi d wi thout i ncreasi ng the bri ttleness ; thi s i s of speci al i m rtance i n

di e casti ng
-
2
The Pb Sb alloy i s used mai nly for quads ; however the fo llowi ng
.
-

compo si ti ons are gi ven by H i om s as examples of regular type metal : Pb 90

1
,

85 80 75 w i th Sb 1 0 1 5 2 0 2 5
, , , , ,
.

— —
A goo d type metal co ntai ns Pb 50 55 Sb 2 5 30 Sn 2 5 1 5 parts As —
, , .

th ese composi ti ons are rather hi gh pri ced a mi xture of Pb 60 Sb 30 Sn 30 -

, , ,

parts i s chosen for ordi nary type .

Bearing metal dem ands two consti tuents one that i s hard to suppo rt the ,

load and one that i s soft to act as plasti c support for the hard grains and to
,

adapt i tself to the fo rm of the revolvi ng surface Thus the Pennsyl vani a
'

.
,

R R uses the eutecti c wi th i ts 87 p er cent Pb and 1 3 per cent Sb In many

. . . . .

case s Sn i s added for the same reasons as i n type metal D etails of ternary .

beari ng metals are gi ven in § 2 6 .

B ullets contai n about 6 per cent Sb . .

E ngravi ng plates are usually composed of Pb 60 and Sb 40 per cent ; often .

,

however the Pb content i s hi gher 80 82 per cent the best plates contai n
,
-

,
-
.

some Sn as e g Pb 80 S b 1 5 Sn 5 per cent ,

. .
, , , .

Battery plates contai n Pb 94 Sb 6 per cent In order to obtai n porous , .

plates for sto rage batteri es H annover beats a plate wi th 96 per cent Pb to the
1
,
.

me lti ng po i nt of the eutecti c and separates thi s by means of a centri fugal

mach i ne .

In the preparati on of these alloys the hard lead of the lead refinery fo rm s the ,

base to whi ch when melted are added the other components In starti ng wi th
, , .

the metals part of the Pb i s melted ; the n Sb i s added ; thi s i s followe d by the
,

rest of the Pb ; and lastly i s added the Sn Another method of Opera ti ng i s to .

°
melt the Pb add the Sn heat the alloy to 500 ,
C and pou r i nto i t the Sb , .

melted in a separate cruci ble If Cu i s to be added i t i s alloyed wi th the Sb .

, .

2 5 Lead Ti n .
— The freez ing poi nt curve has been gi ven i n Fi g 1 4
-
. The -
. .

m i crostructure i s similar to that of Pb Sb alloys except that the Sn grai ns

— -

are more rounded than those of Sb .

Th e two metals are easily uni ted in all propo rti ons and form a seri es of
valuable alloys Some of thei r mechani cal prope rti es have been studi ed by
.

Sperry 11
The resul ts of hi s mechani cal tests are gi ven i n Fi g 2 3
. A summ ary . .

of hi s observati ons and results i s as follows:

Ti n and lead co mbi ne i n all p roporti on The color of t he alloys ranges fro t hat
s . m
of p ure t i n t o t h a t of p ure lea d . In an experi ent ade on t he rolli ng quali ti es, i t m m
1
Cla mer , J . Frankli n I nst , 1 903, CLVI , 4 9 ; E ng . Mi n . J 1 903, Lxx vr, 393 ; Brass World,
1 91 4, x, 85 .

1
Lak e, I ron Age, 1 9 1 1 , ucxxv , 53 2 m .

1
Op ci t , p 34 8
. . .

1
Rev Met , 1 9 1 2 , 1x , 64 1 ; Brass World , 1 9 1 3 , 1x , 2
3 3
m
.
.

1
L 306 Che . mI nd . .
, 1 899 , xv , 1 1 3.
 I N D US TRI AL ALLO YS 29

was found that all the alloys can be rolled i n t he sa me manner as t hat emp loyed f r o

rolli ng t i n The p lasti c alloys are not so

. s flui d as t he non p la t i c com
-

p osi ti ons unless

sup erh ea ted The yellowcolor ca n be p roduced on t he alloys up to and i ncl udi ng
.

Sn, 44 p er cent ; after t hi s poi nt t he lead charact eri st i cs begi n to p redo i nate
. In m .

s t result s, t he
order to o btai n t he be etal ust be poured at t he p rop er t e p erat ure m m m .

It was no t i ced that et al w

“
m ”
hi ch ha d been poured hot , and conseq uently devoi d
of t he yello w film beca me , colored on s andi ng exp osed t to t he ai r for so m ti me
e .

The
“
ti n cry
”
can m
be p roduced f ro t he alloys ( starti ng f ro p ure t i n) up to and i n m
cludi ng S n 50 p er cen t ; i t i s n
.ea rly absent ,
however, i n t he last fewco b i nat i o ns m .

The st rongest alloy i n tensi on is Sn p er cent .

, and Pb p er cent The st rong .

est alloy in co mp res si on i s Sn 7 1 p er cent , and Pb 2 9 p er . cent The ost ductile

. m
alloy i s S n 4 0 p er cen t .
, and Pb 60 p er cent The alloy w i th t he . mo ts reduct i on of

Per Ce nt Z n
Lb p er Bel a . .

“
l l o ng Per cent
A rea Per cent

a s to nn x was w a wu w u ro rs ao es eo es m
Per Ce nt

FI G . 23 .
— Mechanical ro
p p erti es of Pb Sn
-
all oys .

area is S n 5 per cent , and Pb 9 5 per cent The best alloy for ordi nary use is Sn
. .

0
5 p e r ce n t, an d Pb 0
5 p er cent ,
a
.s t he surface of t he bar i s p erfect ly s oot h , and . m
m m m m
[

free fro t he att ed surface found on so e of the ot her alloys The alloys fro Sn .

15 p er cen t . to Sn 30 p er cent i ncl usi ve, are not ho ogeneous ; the outsi de of t he t est
. m
bar fract ure show ed a fibrous nat ure, w hi le t he core consisted of granular at eri al m .

The alloys begi n to assu me a plasti c nature at Sn 34 per cent .

,
and end at Sn 1 5 p er

cent . T he o ther alloys do not p ass through a true p lasti c state, but p ass al ost m
i mmediately f mthe ro soli d to t he li qui d condi ti on I f an at te p t is ade to use . m m
such alloys i n p lace of t he p lasti c co posi ti ons, i t will be found that the m whole mass
wi ll be fill ed w m
i th hard lu p s w m of t he nd
hi ch p revent t he successful attai n ent e .

een t he li m i ts just m
The a loys bet w
“ wi p i ng solders and ”
l enti n d are t he so call d
— o e e ,

i n co m merce are known as 3 and 1 and and 1 Mung r tates that the alloy wi th ,
2 . e
1
s

8
7 p er cent Sn r em ai ns p l
.a s t i c for t h ho rt est p eri od of ti m T h e alloy s showi ng e s e .

t he m o t crystalli ne nat ur are t hose cont ai ni ng from1 0 t

s 0 p er cent of Pb i nclusi v
e o 2 . e .

Th e shri nkag m ore nearly ap p roach e t hat of t i n and is c n i derably l ss t han that of es , o s e

lea d The average shri nk age of sold r m

. ay be sai d to be i n t o t he foot e . .

1
11 4 . I nd .
, 1 9 1 2 , x, 2 90 .
30 M E TALLURGY OF LE AD

T he o ty of the alloys has been determi ned by Plii ss The hardness

vi sc si .
1

vari es wi th the content of Sn Th us Sapozhinow finds that the addi ti o n of

1
.

Sn to Pb i ncrease s the h ardne ss up to 80 p er cent Sn and the addi ti on of Pb .

,

to Sn i ncreases i t up to 30 p er cent Pb; the g reatest hardne ss i s reached w i th .

3 4 per ce nt Pb S te nqu i st ‘
1
p la.ces th e g re ate. st h a rd ne ss betwee n 45 an d 50

per cent Pb . .

—
Th e solubili ty of Pb Sn alloys i n aceti c aci d has been tested by Sack ur 1
,

who finds as was to be expe cted that the co rro si on i ncreases wi th the Pb con
, ,
-

tent bo th metals going i nto solu ti on From the alloy wi th 1 0 p er cent Pb

, . .

there was di ssolve d i n 1 li ter of norm al aci d mg Pb and mg Sn ; . .

of 110 normal mg Pb and mg Sn ; of

,
norm al mg Pb and . .
,
.

mg Sn E lectrolyti c treatment of plates 1 mm i n th i ckness wi th N aOH

. . .

as ele ctro lyte p roved su ccessful i n that the Sn w as di ssolved from the lead leavi ng ,

behi nd a spongy residue .

The method of Ri ch ards (page 2 6) of approxi mati ng the Sb content of -

Pb Sb alloys i s used also for Pb Sn alloy s

— — —
The main use s of Pb Sn alloys are .

those of pewte r solder organ pi pe s stage jewelry toys etc , , ,

-

, ,
.

Pewter does no t co ntai n ove r 2 0 per ce nt Pb ; the lawof France has placed .

the li mi t of Pb conte nt at 1 8 p er ce nt -
.

“
Solder i s u sually made i n three grades and contai ns Pb 34 and Sn 66
11
,

per cent (lowmelti ng po i nt) ; Pb 50 and Sn 50 per cent ( common soli di fies
.
-
.
,

sud de nl y upo n cooli ng ) ; Pb 66 and Sn 34 per ce nt ( be nt for wi p i ng a jo i nt as i t .

,

passes through a pasty stage i n soli di fyi ng) On account of the ordi nary custom .

of usi ng scrap i n the preparati on of solder the presence of from 2 to 5 per ce nt , .

Sb i s not u nusual Bi i s someti mes added to lower the mel ti ng po i nt

. T he -
.

prese nce of the smallest amount of Zn or A1 spoi ls the solder An addi ti o n of .

0 00x per ce nt P i n the form of p h osp hor ti n i s be ne fici al ; a larger amou nt

. .
-

i s harmful I n Germa ny (Law of June 2 5

. so lder used for cu li nary ,

vessels m ay not co nta i n ove r 1 0 p er ce nt Pb . .

Organ pi pes co ntai n 30 p er ce nt Pb ; casket orname nts and stage jewelry

-
.
-

0— 0 per c e nt Pb t oy — 0 e n t Pb
3 4 ; s 4 0 5 p er c . . .

In the prep arati on of the alloy s the Sn i s firs t melted then th e Pb added , , ,

and the whole thoroughly sti rred .

2 6 Lead Antim
. ony Ti n — I t has been shown on page 2 8 t hat Pb Sb
- — -
.

beari ngs are much benefited by the addi ti on of small amounts of Sn These .

te rnary alloys usually go by the name of Whi te Metal or Antifri cti o n M etal .

T hey are also u sed i n di e casti ng 7

The consti tuti onal di agrams of Pb Sn and — -
.

Pb Sb have been shown i n Fi gs 1 4 and 1 5

-

The free zi ng po i nt curve of the . .

-

1
Zt . anorg . Che m .
, 1 9 1 3, 11 01 11 , 1 .

1
J . Russi an P hys Che . m S oc . .
,
1 908, X L, 2
9 , through J . I nsti t . M et , 1 908, VI , 60 .

1
Zt phys Che m 1 9 0 xx x 530 ; J S c Ch m I nd 1 o e 1 9 1 0, xxl x , 2 81

mZ 1 904 Lxm 3 9 ; Z t El e t chem

. . . . . .
, , ,
. .
,

1 Berg H tltlen . . .
, , ,
1 . c ro .
,
1 904 , x , 57 2 ; El ectroche mI nd
. .
, 1 904 ,

n, 3 1 5 .

1
Li p p mann History of the Art , ,
”
Che mZ . .
, 1 9 1 1 , xxx v , 437 .

1 E di tor, Brass World 1 90 7 111 66 1 ; , , ,

191 1 , V11 , 1 93 .

7 Lak e, Mechani cal World , 1 9 1 4 LVI , , 64 ; J . I nst . Met ,

1 1
9 4, x11 , 304 .
32 M E TALLURGY OF LE AD

Sn i n solu ti on, ) and a soli d

oluti on of Sn i n Sb or of Sb i n Sn The most fusi ble
s .

—
al loy i s the Pb Sn eute cti c O wi ng to the great di fi erence s i n specific gr avi ty
.

of the Pb crystals and the soli d solutio ns of Sn Sb the alloys show a con
—
,

si derable te nde ncy to segregati on The i ndustr i al alloys are composed of Pb.

and soli d so luti o ns of Sn Sb

—
.

The tri axi al di agram of H eyn Bauer Fi g 2 8 gi ves the i sotherms of the -

, .
,

di fi erent alloys and a li ne E gd

,
i n whi ch the alloy b ( wi th Pb 80 Sn 1 0 S b , ,

1 0 p er ce nt ) and t he alloy d (wi th Pb

. Sn Sb 4 per ce nt ) rep resent .

the ternar i es i n the begi nni ng and the end of a fusi on or the ,

C1 Per Cent Sn
FI G . 28.
— Tri axial di agra m — —
of Pb Sn Sb alloys wi th i so ther m s .

ficati on temperatures coi nci de The li ne bd represents a seri es of alloys i n

,
.

whi ch melti ng and freezi ng poi nts approxi mately coi nci de Alloys i n whi ch
-
.

these phenome na are far apart show segregati on i n slow cooli ng Thi s dif .

ficulty i s i n part overcome by add i ti ons of from 2 to 3 per cent Cu as Cu .

,

rai ses th e temperature of first retardati o n occurr i ng i n coo li ng whi le i t leaves ,

unchanged the last .

The greatest hardness is reached accordi ng to H ey n Bauer wi th an alloy ,

-

of the composi ti on Pb 1 0 Sn 30 Sb 60 p er cent The hardness of Pb Sb i s

, ,
.
-

—
i ncreased by Sn that of Sn Sb by Pb th at of Pb Sn by Sb In general
—
, ,
.
,

bri ttleness increases wi th hardness except for a seri es ofSn ri ch alloys wi th less ,
-

th an 2 5 per cent Sb whi ch show toughne ss greater than that expe cted from
.
,

the hardness Resi stance to compressi on i ncreases wi th hardness An

.
1
.

addi ti o n of Cu i ncreases the hardness as well as the br i ttle ness and e speci ally

so wi th qui ck coo li ng .

1
See also Charpy, lac . ci t , p . 2 3 0.
 I N D US TRI AL ALLO YS 33

2 7 Lead Arseni c
.
— The freezi ng poi nt curve has bee n gi ven i n Fi g 1 6
-
.
-
. .

The o nl y i ndustri al alloy i s shot whi ch contai ns less than 0 5 per ce nt As

1
. . .

Fi ne sizes contai n p e r c e n t A s med i u m a n d c oa r se per c e n t Th e .

,
.

alloys are hard and bri ttle Shot i s manufactured by po uri ng the alloy i nto .

a perfo rated i ron basi n on the top of a tower of consi derable hei gh t whence i t ,

drops i nto a vesse l filled wi th cool water wh i ch contai ns a small amount of

N ass and i s covered wi th grease The use of centri fugal apparatus and of .

compressed ai r for the m anuf acture of shot are menti o ne d The shot from .

the tower i s not uni form and has to be sorted Thi s i s accompli sh ed by ,
.

means of a movi ng round table over whi ch the spheri cal globules fed at -

the center wi ll tr avel qui ck ly whi le the mi sshaped will travel slowly and fall
, ,

i nto a separate pocket In some plants si zi ng scr eens and i n o ther s i ncli ned .
, ,

fla t tab le s have rep laced round tables .

2 8 O th er Lead Alloys
.
— A number of bi nary and ternary alloys of m i nor
i mportance than those gi ven above have been put on the m arket .

B i nary Allays — Some of th ese are .

1
—
Pb B i — The all oys are malleable as long as the Pb co ntent exceeds that
.
-

of Bi ; they are dark gray and are stronger than Pb The alloy 1 Bi : 2 Pb can , .

be rolled i nto sheets The alloys on the whole are of li ttle i mportance . .

2 P b Cd .
— A seri es of alloys w
-

. i th from to per cent Cd has been .

p a t e n ted by T ou ced a
1
w hi ch i s to se rve a s be a ri n g met al ,
.

3
°
P b—M —
.
g T he se a lloy s
1
fo rm . the c h em i ca l c ompou n d P n g fr ee z i ng at ,

5 2 1 C an d two eute
.
,
c ti cs o n e w i t h ab o ut 6 8 per c en t Pb f reez i ng a t th e ,
.
,

o ther wi th about 96 per cent Pb freezi ng at 2 50 C An all oy wi th per .

,
°
.

cent M g i s sai d by Mofi et to be valu able for antifri cti o n purpo ses
1
. .

— — The co nsti tuti on has bee n noted i n § 1 7 An alloy wi th Pb

4 Pb Ni . . .

6 — per e nt n d N i — per e n t h be n p ate n ted by A ll e n 11

w hi c h
9 5 99 5
. c a.
3 5 0 5 c a s e . . . .
,

he clai m s to be stronger and less corrodi ble than other alloys of si mi lar na ture .

Ternary All ays —

A few of these m ay be menti o ned whi ch have bee n t e
.

— — — —
cently stu di ed : Pb N i Cu ; Pb Sb Cu ; Pb Sn Cu ; Pb Sn Zn ; Pb Sn Bi ;
° " — — 1 — — ° — 1° -

— — n 11 —
Pb Ag S ; Pb Cd B i and fusi ble alloys z Pb Cd Bi Sn
— 11 — — 11 -

1
Wettstei n M et ,
I nd .
, 1 9 1 0, v m3 ,
.

Scott, p
o . ci t , 1 9 1 4 , x11 , 2 4 5 .

1
U S Patent N o 89 74 3 1 , Sep t 1 , 1 908
. . . . .

1
Grube, Z t anorg Che , 1 90 5, X LIV, 1 2 4
. . m . .

KurnakowStepanow , op ci t ,
1 905, XLVI ,
-
. 1 84 .

1
Metallurgi e ,
1 906, m , 2 26 .

1
U S Patent N o 834 099 , Oct 2 3, 1 906
. . . . .

1
Pat t a vano Mazzet ti , Gaeetta chi i tal , 1 9 1 4 ,
-
m . . x uv ’
, 3 75 ; J I nsti l . . Met ,
v, 2 34
1 9 1 5, x r .

1
Charpy, lac ci t , p 2 3 2 . . .

1
Ca rnevali , Che mZ . .
,
1 91 1 , no w 509 ,
.

Charp y, lac ci t p 2 36 . . .

1
Levi M elvano Cecca relli , J I nsti l
- -
. . Met ,
1 91 2, VI I , 2 78 .

11
Charp y, lac ci t , p 2 1 8 . . .

Shep ard, Th esi s, I thaca , N . Y .

, 1 903 .

Parravano, I nternet Z t Metallographi e, 1 9 1 2 , . . II , 1 5 .

11 Parravano, op cit , 1 9 1 1 , 1 , 89 , 1 9 1 3, 111 , 1 5 . .

11 Barlow, Zt . anorg . Che m .

, 1 91 1 , 1 78 .

11
Stoflel, op ci t , 1 907, . 1 37 .

Pat t avano Si rovi ch, J -

. I nsti t . Mot ,
1 9 1 2 , VII I 3 2 2 .
 C H AP TE R V

LEAD COMPOUNDS

29 .Lead Oxi de and per cent Pb —

Carbonate Lead oxide, PhO .
,

2 0 7Pb+ 1 60 = 2 2 3PbO + 50800 cal has been found i n a ve i n wo rked for

1
,
.

orp i ment ; i t goes by the name of massi cot and has only mi neralogi cal i n ,

terest It i s obtai ned on a large scale as m

. assi cot and li tharge whi ch have ,

di ffe rent physi cal properti es Massi cot an amorphous yellow powder i s .
, ,

formed by heati ng lead on a flat hearth to a lowred hea t removi ng the film ,

of suboxi de as fast as i t forms and o xi di zi ng i t to ye llow oxi de If the , .

temperature be rai sed to the mel ti ng po i nt that i s to a bri gh t red

— -

,
-

hea t and the fused oxi de coo le d i t soli di fies as crystalli ne li tharge
—
, .

Li tharge i s obtai ned on a large scale by cupelli ng argentifero us lead It .

i s soft and greasy to the touch and ge ne rally crystalli zes i n orthorhomb i c
octahedrons Terni er and Le Chateli er have found tetr agonal for m
.
1
s Lar .

son di sti ng ui sh es red tetrago nal m as si cot and yellow ortho rhombi c li tharge
1
.

Whi le molten i t is transparent and orange colored when cold i t i s opaque -

and i ts color vari es from yellow to red accordi ng to the rate at wh i ch i t

has coo led ; qui ck coo li ng p romotes the yellow slow coo li ng the red co lor , .

Yellow li tharge i s produced on a large scale by allowi ng i t to run from

the fur nace over an i ro n p late and chi lli ng i t wi th water if necessary ; i t ,

i s th us obtai ne d i n small lumps The red flaky vari ety i s formed by allow .
,

i ng the ru nni ng li tharge to collect i n fro nt of the furnace i n cakes of fro m

1 to to ns i n wei ght and to cool slowly The inner part of a cak e wil l
,
.

swell up and fo rm flakes of red li tharge ; the outer and lower p arts h av i ng coo le d ,

qui ckly wi ll remai n so li d and have a yellow color Thi s swelli ng i s ca used
,
.

by the gi vi ng ofl of oxygen w hi ch molten li tharge ab sorbs In soli di fyi ng , .

qui ckly i n sm all lump s the oxygen o nl y makes the surface uneven ; i n cooli ng

slowly i n large lumps the oute r soli d cru st ob stru ct s the passage of the o xygen .

Thi s prevents the i nner part from so li di fyi ng firmly and causes i nstead th e ,

formati on of loose flakes The flakes and lumps are separated by si fti ng Both
. .

vari eti es when ground have a reddish yellow colo r

, ,
-
.

Preparati on i n thi s way has no metallurgi cal i nterest .

°
The melti ng po int i s 883 C or 1 -
I t i s volati le i n a current of ai r .

1
M i neral Mag . .
, 1 9 1 4 , XVII I , 1 43 .

1
Berg H ittten . mZ . .
,
1 89 5, LIV, 4 5 2 .

1 Am Mi n . eral . , 1 9 1 7, II , 1 8 .

1
Mostowi tsch M etall nrgi e , , 1 90 7, IV, 64 7 .

1
Schenck -
Rassbach , Ber deutsch . . che mC . esell .
, 1 908 , x u , 2 9 1 7 .

34
 LEAD COMP O UN DS 35

°
at 800 very deci dedly so at 9
C .
1
The di ssoci ati o n temperature for
and
°
Pb and 0 has been calculated as 2 34 8 C ; the specific heat at 2 3 C i s
1 °
. .

i t i s a goo d condu ctor of electr i ci ty when mo lte n .

Li tharge i s a strong base and qui ck ly corro des aci d furnace materi al w i th ,

whi ch i t form s a si li cate I t i s an excellent flux formi ng fusi ble compounds .

,

wi th oxi des that are i nfusi ble alone They do not al ways enter i nto che m i cal .

combi na ti o n wi th i t but often are si mply held i n i gneous soluti on by an excess ,

of li tharge Thus fu si ble m i xtures are formed wi th CaO B aO MgO and

.
, , ,

A120) Tab le 9 gi ves the amounts of li th arge requi red to form fusi ble mi xtures
.
1

wi th the pri nci pal metalli c oxi des .

T AB LE — SconI rVI N G E xrE crs or LI rnAnGIz

9
-
.

“ —
The i nvesti gati on of Cummingham of the sy stem PbO CuO up to 70 per
ce nt CuO has sho w
. n the ab sence of chemi cal compo unds and th e pre se nce of
°
an eute cti c wi th 3 2 per cent CuO freezi ng at 689 C Thi s exp lai ns the well .
,
.

k nown fact that i n cupelli ng coppery li tharge flows more readi ly than li tharge, ,

free from Cu .

Li tharge readi ly gi ves up i ts 0 Thi s i s see n from i ts behavi or wi th S Te .

, ,

As Sb S n Bi Cu Zn Fe
,
“ , , , ,
.
,

They become wholly or partly oxi diz ed and the oxi des are ei ther volati li z ed ,

or scorified by the surp lus of li tharge a corresp ondi ng amount of lead whi ch , ,

combi nes wi t h any u no xi di z ed part havi ng bee n redu ced PbO begi ns to act ,
.

upo n Fe at about 9 2 5 C ’ °
.

Reducti on by C i s noti ceable at 4 00 500 i s very deci ded at and more so

° °
at 700 C Reducti on by CO to Pb begi ns at 1 60 1 85 C PhO passi ng t hro ugh
.
— .
,

the state of s O ; B ri slee

1 1°
gi ves Reducti o n by H to PbgO begi ns

1
Doeltz Grau M etal lurgi e 1 906
-
mann , , , 11 1 , 407 .

1
Hofman W anjukow, Tr A I M E -
. . . .
, 1 9 1 2 , x u n, 54 3 .

1
Stahl Metall urgi e 1 90 7 IV 68 2
, , , ,
.

“Tr
1
Bert hi er, ai té des Essai s, 1, 51 3 .

“ ”
Percy, Lead, p 1 6 . .

1
Zt anorg Che , 1 9 1 4 , l xxxrx , 4 1 8
. . m . . .

1
Berthi er, lac ci t , p 382 . . .

Percy, op ci t , p 1 8 . . .

7
Fri edri ch , S tahl u E i sen, . 1 9 1 1 , xxx r, 2 04 0 .

1 Doeltz Grau -
mann M ,
etall nrgi e, 1 90 7, Iv, 4 2 0 .

Bri slee, J , Chem S c . o .

, 1 90 8, x cnI , 1 54 .

1
Borchers, Metallurgi e , 1 904 , I , 2 9 5 .

Fay Seek er Lane Fergusi on, Brookl yn Polytech E ngi neer,

- - -
.

xc1 , 4 06 .

11
Loc . ci t
36 ME TALLURG Y OF LE AD

°
to Pb at 2 3and Fay Seeker Lane Fergusi on gi ve 1 90 as the 1
at - - -

lowes t temperature .

Reacti ons wi th PbS are taken up i n § 4 1 .

PbO i s sli gh tly soluble i n H alo ( 1 p art i n readi so i n aci ds and al

kali The best solvent 13 KN Os; H F di ssolves i t spari ngly ; H Cl converts i t
.
1

i nto PbClz; H gSO4 i nto PbSO4 ; H gs changes i t i nto PbS ; H I i nto PbI g ; alkali
soluti o ns co nvert i t i nto plumbate e g K2 Ph ( oH ) o Thi s 18 stable at 1 00 C
°
. .
, . .
,

but i s decomposed at a hi gher te mperature : Kn ( OH ) o+ heat = 2 KOH +

Pb0+ 0+ 2 H zO .

Lead carbona te, e t Pb ; 2 07Pb+ 1 2 C+4 8O = 2 67

PbCO. p er c n .

PbCO ; Thi s occurs as cerussi te It i s a poor co nductor .

of electri ci t y ‘
The wh i te lead of comm . er ce i s a basi c carbonate PbCO ; .

i s li ttl e soluble i n H zO ; th e solubi li ty i s grea tly i ncreased i n th e pres ence of

C02 ; i t i s soluble i n br ine “ I t i s de composed by heat under the parti al pres .

°
sure of C03 at 3 1 5 C the di ssoci ati o n temper ature i n a current of ai r ough t
.

.
—
to be lower The reacti on PbCO a+ heat >PbO + COg i s non reversi ble at " -

l east i n th e absence of moi sture .

3 0 P l u
.m b i te s a nd P lu m ba te s —T he o x i des P b O an d P h o a fo rm p l umb i te s .

and plumbates wi th alkali alkali earths and some metalli c oxi des , , .

Pl um bi tes M g PbOz Di ssolvi ng PbO i n an aqueous soluti on of or i n mol ten

’
.
,

KOH forms u nstable Ks Oz whi ch i s readi ly oxi dized to the plumbate

w ho. if ai r i s i ntroduced .

Plum bates M g Pboa Th ere exi st tw o classe s : m etap lum bates ( H 3Pb03)
'
.
,

and orthop l um bates Of the latter the calci um plumbate ,

Can 04 has bee n referred to i n connecti o n wi th blastroasti ng “ I t i s formed .

,

by heati ng Ca ( OH ) g ei ther wi th P hog or wi th PbO ai r havi ng free access The ,

.

compound i s stable i n dry ai r free from C03 I t i s decomposed by aci d i nto .

calci u msal t and PM ” at ordi nary tempe rature by CO , when suspended i n

°
H zO ; by boi li ng wi th H N aCOa; by H gO alone at 1 50 C The dry salt i s de .

1 °
composed between 9 50 and 1 0 2 0 C .

L e ad F e rr i te — I t i k n o w n th a t i n th e cru ci ble assay the presence of

3 1 . s

Fe. o. acts u nfavorably upon the yi eld of Pb The usual i nterpreta ti on i s .

th at Fezoa oxi di z es some of the reduci ng agent ; Koh lmeyer on the o th er hand
1°

at tri bute s i t to the fo rmati on of a compou nd of Fe. o. and PbO Inve sti ga .

ti o ns of the system PbO Fegog leads hi mto the conclusi on that there exi st
— 11

1 Glaser , Zt . anorg . Che m .

,
1 903, xxx vr, 1 3 .

1 Loc ci t

m 1 90 m m
. .

1
J g
li er,
Z t anorg Che . . .
,
1 , ,
22 .

H i lttenm Z
'

1
Ki li a ni , Berg . 883 X LII . .
, 1 , ,
2 3 5, 3 75
1
Met ChemE ng , . . 1 9 1 6, xrv, 3 1 .

1 Fri ed ri ch , S tahl n E i sen, . 1 91 1 , xxx r, 1 909 .

7 Debray , Co p t rend , m . . 1 8 78, Lxxx vr, 51 3 .

1 Borch ers, Metall nrgi e, 1 905, 11 , 1 .

1 Le Chateli er, Co pt rend , m . 1 894 , cxvn, 1 09 .

11
M etollnrgi e, 1 9 1 0, V11 , 2 89 .

11
09 ci t .
1 9 1 3. x , 44 7, 4 83 .
 LE AD COMP O UN DS 37

probably five che mi cal compounds , 3P bO 3 Fe2

.0 3;

mm
2 PbO . 3Fez O s; and PbO . 2 F6 3 03, all of whi ch are decomposed upon fusi o n
and form ternary mix tures of PbO FeO and Of these at leas t , , .

one chemi cal comp ound i s be li eved to be formed Th e .

mel ting poi nt of PhD i s depressed 1 33 C through the addi ti on of 1 2 p er cent

-
°
. .

by wei ght of F0201 .

32 L e a d Sili
. c a te s — T h ere oc c u r t wo s il i ca tes b a ry sili te 3P b0 2 5 i 0 3 .
, ,
.
,

and alamosi te PbO Si O z whi ch have only mi neralogi cal i nterest ,

Th e .
,
.

co nsti tuti o n of lead sili ca tes w as fir st studi ed by Si m mons and Mani h ot

1

Ki eser and later by Mostow

1
,
i tsch 1
The last concluded that there exi sted .

no real compo unds and that the sili ca tes w ere soluti o ns of PbO i n lead glass
,
.

Thi s posi ti on has bee n co ntroverted by the researches of Cooper Shaw -

Loomi s 1
H ilpert Weil er,
“ and H i lpert N acken
1
The curve of H il pert
- -
.

N acken Fi g 2 9 show s three chemi cal compou nds 2 Pb0 Si 03 3PbO 2 Si Og

,
.
, , .
, .
,

and PbO Si Oz whi ch have bee n further establi shed by opt i cal analysi s and
’
,
.
,

th ree eute cti cs ; one of PbO 2 PbO — .

°
Slog freez i ng at 71 7 C ; a se cond
,
.
,

2 PbO Si Or 3PbO 2 Si 03 ; and a thi rd

. .
,

3 PbO 2 S i O g
. PbO S i 0 3 bot h of -
.
,

whi ch freeze at 670 C The uni o n °

.

of th e components begi ns at
“
i s sl ow at and i ncreases rapi dly

wi th the temperature Mostowi tsch ’

.

has shown that m i x tures of PbO and

Slog rangi ng i n compo si ti on from
6Pb0 Si Oz to PbO Si Og begi n to
. .

softe n at temperatur es lyi ng betwee n

1 1° 1 ° 1 ° 4° 5° 1 ° 7° 8° 9° 10 °
° P“ c m " ” a 8 10 1
7 00 a nd 75 0 C th a t i s c o nsi de r a b ly
FI G 2 9 — Freezi ng p o nt curve of system
.
, ,

below the me lti ng po i nt of Pho

Pho
i -

,
. .

whi ch li es at also that the

me lti ng poi nts of lead glasses i n general are lowered as the Si Oz content i s -

i ncreased Thus the subsi li cate 4 Pb0 Si 03 i s complete ly li quefi ed at

. .

the si ngulosili cate 2 PbO Si O z forms a Vi scou s li qui d at , and requ i res .
,
°
9 4 0 C to flow re a d
. il y T h e s e d a ta do not qui te agree wi th tho se to be .

re a d from the curve .

Th e fu si ble si li cates are yellow and become darker i n p roporti o n to the

quanti ty of PhO th ey co ntai n T hey ch ange thei r color if they are co ntam i .

1
J Che
. m
S oc , 1 903, oon/111 , 1 4 49 . . m .

1
Li ebi g Ann Che , 1 90 5, 000 11 11 , 3 56 . m .

1
Metall nrgi e , 1 907, IV, 64 8 .

1
A Che m J , 1 909 , XLII , 4 61
. m . . .

1
Ber dent sch Che .Gesell , 1 909 , '
. m . . X LII , 2 969 .

1
Op . ci t , 1 9 1 0, 2 565 ; M etallurgi e ,
1 91 1 , V111 , 1 57 .

1
Cooper Kraus Klei n, Am Che J - -
. m . ., 1 9 1 2 , X LVII , 2 73 .

1
Hil pert . Metallurgi e. I 908. V. 535
1 Metall urgi e , 1 908, V, 535; Tr A I . . . M E . .
,
1 9 1 6, LV, 744 .
38 ME TALLURG Y '
OF LE AD

nated wi th other metalli c oxi des be seen if lead is slagge d i n a scorifier; , as can

eg
. . Fe co lors b rown ; Cu green; Mn purple b lack ; N i browni sh yellow ; Co
, , ,
-

,
-

blue ; Te yellowi sh red the colors growi ng dark i n proporti on to the oxi de
,
-

added .

°
H ilpert h eated m i x tur e
1
s of the compo ne nts severally to 930 and
C and found that at 930 o nl y 2 Pb0 Sl03 showed loss by volat ilizati on;
°
. .
,

that at ag ai n 2 Pb0 Si Oz gave the grea te st lo ss and w as followed by .

PbO Si Og ; and that mi x ture s wi th hi g her percentages of Slog experi enced no

.

lo ss whatever .

Lead sili cates are much used for glazi ng ti les pottery etc Thei r behavi or , ,
.

has been stu di ed by Seger and Cramer 1

.

The lea d from sili cates i s not readily li berated by the or di nary reduci ng
agents S ulph ur decomposes the si ngulo sili cate to some exte nt but i t has
.
-

less efl ect on the bi si li cate ; FeS throws do w n some Pb a double si li ca te of -

lead and i ro n bei ng the result ; C redu ces from a bi sil i cate p art of th e Pb -
.

In order to extract all the Pb i t must be first set free fro m i ts combi nati on
wi th Si O z by a basi c flux ; thus Fe decomposes all fusi ble lead sili cates at a
bri ght red heat provi de d e nough i s added to form a si ngulo si li cate ,
-
.

The si ngulo sili cate and bi sili ca te of lead are readi ly decompo sed by ni tr i c
- -

aci d th e tri si l i cate i s not comple te ly decomposed ; th e more aci d the sili cate
,
-

the less i s i t soluble .

— Fusi o ns of PbO and B 30; gi ve glasses whi ch are colorles s

33 Lead Borates
. .

or li gh t yellow and i ncrease i n h ardness wi th the co ntent of B 203 Le C hateli er

,
1
.

prepared the compou nd PbO 3BgOz by fusi on of the components and removal .

of the excess of B20; wi th H 20 Accor di ng to Guertler the oxi des PbO and 1
.

B 30; are o nly p artly mi sci ble at temperatures below 6 2 0 C fu si ons w

°
i th
0 g PbO 1 g E gos form emulsi o ns ; wi th over 0106857g PbO they form
. . .

glasses .

34 Le ad C hl o ri de P bC l e nt Pb 0 P b+ Cl = 78
.
, z per c ; 2 7 7 1 2 .

PbClz+ 83 900 — It i s forme d i n the dry w

, ay by the acti o n of Cl upon Pb ,

and i n a chlo ri di z i ng ro ast of Pb and i ts compounds It i s cry stalli ne or amor .

°
pho ns dependi ng upo n the mode of preparati o n; mel ts at 498 C boils at .

°
9 h as a spe cifi c h eat of between 2 60 and 498 C and of between .

° °
49 8 a nd a spe ci fi c re si stance rangi ng f rom 1 39 5 to 1 94 1 oh ms betwee n 4 98

and It is soluble i n bo i li ng water f rom whi ch i t crystalli z es i n rhombi c

"

crystals upo n coo ling ; i s sli gh tly solub le i n col d wate r less so i n w ate r co ntai ni ng ,

a li ttle H cl the solubili ty i ncreasi ng w i th the co nte nt of H Cl ; soluble i n alk aline

,

1
Loc . ci t .

1
Thoni ndus tri e Z .
,
1 89 3 , XVI I , 1 2 2 4 ; B erg H atten
. mZ . 1 894 , L1 11 , 1 1 .

1
m
B ull S oc Chi . . .
, 1 899 , xxx, 35 .

1
Zt anorg Chem
. . .
, 1 904 , X L, 2 2 5 .

1
Good wi n Kalmu -
s, P hys Rea , . 1 909 , xxvrrr, I .

1
W eber , Zt . anorg . Che m.
, 1 89 9 , xxx, 0
3 5 .

1
Auerbach Plei ssner, -
Ueber di e L6sli chkei t ei ni ger Blei verbi ndungen i n W asscr,
er
g , Berli n, 1 90 7 .
40 ME TALLURGY OF LE AD

unchanged at a hi gher temperature ,

decomposed at an elevated temperature
by H and S i n the cold by H 3804 ,
.

1—
3 7 L ead Fl uos
. il i cate, PbS iF o p er cent P b) I t i s fo rmed by th e . .

acti o n of E l F o upo n PbO wh en so me Slog i s p reci p i ta ted ; crystalli zes fro m

soluti on wi th 4
°
m
ol H gO ; di sso lves at 1 5 C i n 2 8 p er ce nt of i ts we i gh t of
. . .

°
H 20, fo rmi ng a syrupy soluti o n of sp gr ; mel ts at 60 C wi th water of . . .

y t
cr s alli za ti on H eati ng a neutral soluti o n. ca s s ue a parti al decomposi ti o n
i nto i nso luble b asi c salt and free H l F s .

Nor mali ty of Salt

— i d i i f H Si F f FI G 3 1 — E
FIG .
3 0 .E lect r c co n uct v t y o , . o . . lect ri c conducti vi ty o f PbSi F .
difl erent
'

nor mali ti e
s of PbSi F . di ssolved i n when di ssolved i n different nor mali ti es of

aci d . H ’ Si FQ .

The electri c co nducti vi ty of H gSi F . and of PbSi F. has bee n studi ed by

1
P atti nson H is results are summari z e d i n Fi gs 30 and 3 1 ; they show at a
. .

glance the great eflect free aci d has i n i ncreasi ng the conducti vi ty of th e
electrolyte .

'

E lectro lysi s does not decompose H gSi F . si mply i nto H and H Si F o ; th ere
'

exi sts a tendency toward the decompo si ti o n i nto Slog and H F whi ch comb i ne
agai n u nder th e i nfluence of ci rculati on and di ffusi on .

38 L ea d S e
.leni de an d T elluri de —L e ad sel emd e PbSe per ce nt .
’

, .

Pb ; 2 07Pb+ 79 Se = 2 86 PbSe+ 1 7 000 cal ) occurs as clausthali te ; i ts freez ,

.

i ng po i nt curve has been noted in § 2 2

-
I t i s formed by di rect uni on of com .

1
Bet ts, Tr A I . . . M . E .
, 1 904 , xxxxv, 1 75 .

1
Met . Che mEng. .
,
1 9 1 3, xx, 6 70.
 LE AD COMP O UN DS 41

ponents or by reducti on of selenate wi th H C or AI ; i s readily subli med ;

1
, ,

i s decomposed by roasti ng .

Lead telluri de PbTe p e r ce nt Pb ; 2,

07 P b+ 1 2 6 T e 333 P bT e + .
-

333 ca l ) occ urs as a

. l ta i te ; i ts freez in g po i nt curve ha s b ee n n ote d i n § 2 2 I t i s -
.

formed by di rect uni on of the ele m ents i s readily subli med and decomposed , ,

by roas ti ng .

Sele ni des and tell uri des are found i n the anode mud formed i n the elec
trolyti c refi ni ng of copp er and lead They des erve consi derati o n as the mud .
,

form s the rawm a ter i al for the producti o n of Se and the Te for whi ch t here , ,

i s no market at present i s the bane of the refiner i n produci ng fine si lver or ,

39 Le a d S.u l phi de, PbS p er c e nt Pb,

2 0 7Pb+ 3 2 S = 2 39PbS + 2 0, .

2 00 — Thi s occurs as galena The exi ste nce of subsulp hi des ( Pn , .

Pb4S) beli eved i n by o lder metall urgi sts and doubted by Percy has been di s
11 1

posed of by Fri edri ch Leroux , whose freezing poi nt curve i s gi ven in Fi g 32

1 - -
. .

Thi s sh ows two unbroken li nes ; the crystalli

zati on of PbS begi ns at 1 1 03 C and soli di so mnorms °
.

ficati on of the mi x ture i s complete d at

the mel ti ng po i nt of Pb -
.

Rii ssler found that PbS di ssolved i n Pb

1

woul d crystalli ze upon cooli ng i n cubes , ,

arranged i n step form resembli ng those -

whi ch are frequently seen i n wall and hearth

accreti o ns of b last fur naces
“ -
.

PbS i s formed i n the dry w ay by heati ng

Pb and S or PbO wi th an excess of S or by

, ,

reduci ng PbSO . wi th carbo naceous matter 1

Fm 3 2 curve
.

. °

The reducti on of PbSO. i s taken up i n §4 0 .

In the wet w ay PbS i s prep ar ed by p reci p i

tati on from sol u ti o n wi th H ’ s The sulp hi de produced i n the dry w ay .

has the same properti es as galena ; preci pi tated amorp hous PbS is rendered
crystall i ne by heati ng wi th excl usi on of ai r .

°
Th e mel ti ng poi nt i s gi ven as rangi ng from 93 -
to 1 1 2 0 C ; the last
1
.

fi gure i s the one generally accepted The sulphi de i s very fl ui d when mel ted .
,

1
Rossler, Z t Che , 1 89 5, xx , 4 1
. anorg. m
m
. .

1 Bredberg, E rd ann J Olson Che , 1 82 9 , . . m . V, 2 3 7, 1 83 1 ; xxx, 2 87 ; Poggendorf Ann , . 1 82 9 ,

V11 , 2 68.
“ ”
1
Lead. 39
‘
Metall m i c. 1 905. n. 536 .

1
Zt . Cheanorg. m .
, 1 89 5, x
x, 41 .

1
Illustrated i n Plattner, C . F, . Di e Metallurgischen Rbstp rocesse, E ngelhardt,
Frei berg, 856, p 2 0 1 1 . .

1
Boudouard, Bull S oc Che . . m .
,
1 90 1 , xxV, 2 84 .

1
m
Lodi n, Co pt rend , 1 89 5, xx , 1 1 64 . . .

1 F
ri edri ch , Metallurgi e, 1 908, V, 2 3 .

Biltz, Zt anorg Che , 1 908, L111 , 2 73

. . m . .
42 ME TALLURG Y OF LEAD

and p enetrates the firebri ck

of the furnaces in whi ch i t i s treated ; often a net
work of small vei ns of bri ght crystalli ne galena is found in fur nace li ni ngs I t -
.

i s volat ile be low i ts melti ng po int Doeltz Graum ann heati ng galena i n an
1 -
.
-

at m osphere of N found that subli m ati o n took place at 860 C whil e Bi ltz 1 °
.

A more recent research of Schm

°
noti ced i t only at 9 ehl gi ve s 600 as the
1

temperature at whi ch PbS i s partly volatili zed On the walls of blast furnaces .
-

crystals of sub li med gale na are of common occurre nce T he speci fic heat of .

°
crystalli zed gale na betwee n 0 and 30
°
0 C i s G ale na i s a good con .

ductor of electri ci ty numeri cal data are gi ven by Gui nch ant and Aubel “ 1
.

The relati ons exi sti ng betwee n Pbs and other metall i c sulphi des are di s
cussed u nder Co nsti tuti on of M atte § 1 80 ,
.

PbS i s decompo sed i n the dry w

°
ay by heating to 600 C i n a curre nt of H
1
.
,

the reacti on PbS + H g+ Pb+ H gS bei ng reversi ble ; by roasti ng ; and by

—1

fusi on wi th a metal whi ch has a strongerafi ni ty for S than has Pb .

° °
I n ro asti ng o xi dati o n beg i ns at 360 to 380 C accordi ng to the wri ter s ex
’
, .

p e ri m ents w i th 1 00 me sh g ale na T he fi gu r e s o-
f F ri ed r i ch ’
55 4 a nd 8 4 7 C .
,
° °
.

as the i gni ti o n tem p erat ur e rs i n O for p a rt i cle s of m m a n d ove r m m i n . .

si ze appear to be too hi gh Plattner states that i n roasti ng finely ground

10
.
,

galena careq y at a temperature sufli c i ently l owto prevent i ts becomi ng pasty ,

it w i ll be first co nverted i nto Pho (perhaps onl y i nto PbgO) and PbS
does not oxi di z e read ily hence 80, wi ll form slowly ; part of the SO, combi nes ,

wi th the 0 of the ai r and for m s $ 03 by cataly si s and thi s comb i nes wi th PM ,

to form PbSO4 ; if PbgO i s present the SO; first converts i t i nto PbO The
melsberg that some PbS is di rectly oxi diz ed to PbSO .
.
,

suggesti on of Ram
u
,

wi thout passi ng through the stage of PbO does not app ear to be vali d as the , ,

reacti on M S + 2 0, — >M $ 04 i s not reversi ble “ 1

Under ordi nary co ndi ti ons the .

p roduct of a ro ast is a mixture of PbO and PbSO. Thus Plattner i n roasting 11

.

pure galena obtai ned the proporti on 5PbO : 2 PbSOr The r ecent r esearch of .

Dem w °
p o lfl 11
show s th at if a ro as t i s ca r ri ed o n at a temper a ture be l ow 4 5 0 C .

there i s formed mai nly PbSO. and th at wi th slow oxi dati on i n the presence of ,

a catal yzer the enti re PbS m ay be converted i nto P hso4 On th e other .

hand the more the temperature ri ses above 4

,
the greater wi ll be the
amou nt of PbO fo rmed ; if i t i s r ai sed above 7 the reacti on between PbS
1
Metallurgi e ,
1 906 , 111 , 44 1 .

1 Lac . ci t
1
Di ssertati on Darmstadt , , 1 91 4 .
1 Tilden, Proc Roy S oc , 1 907, . . . 2 20.
1 Ki li ani , Berg H iltten Z , 1 883, . m . . x u x, 2 35, 3 75 .

1 Co ptm rend 1 90 2 , cxxxxv, 1 2 2 4

m
, .

1
Op ci t
.
, 1 902 , eow 4 56 , , 734 .

1 Sch mehl , op. cit

1
Metallurgi e, 1 909, VI , 1 7 .
0

Op ci t
11
.
, p . 1 4 5.
11
Percy Ra -
mml be g e s r , Di e Metallurgi e des Blei es, Vi eweg Brunswi ck
, , 1 872 , p 39 . .

11
Vondrfi ek , Oest Z t Berg B lata nt . .
,
1 906 , LI V, 4 37 .

11
Lac . ci t.
11
Metall . n . Era , 1 9 1 4 , xx, 61 9 .
 LE AD COMP O UN DS 43

and PbSO. wi ll begi n

the Pb set free wi ll be oxi di zed by , and

cup ell a ti on The experi ments p rove the generall y accepted rule that slow
.

roasti ng at a low temperature produce s more PbSO. than if the operati on i s

ca rri ed on q ui ckl y at a h i gh temperat ure Thi s may be e xpr essed by
.
.

( slow roast)
3PbS + 1 00 = 2 PbO + PbSOr+ 2 SO g ( qu i ck west )
Th e propor ti ons of PbO and PbSO. formed are dependent not onl y upon the
temperat ure and amount of r abbli ng but are governed largely also by the ,

character of the mi neral s associ ated wi th the gale na i n the ore Th us P lattner 1
.

i n roas ti ng g alena from Blei berg C ari nthi a whi ch co ntai ned a small amount , ,

of blende and pyri te obtai ned in hi s product the rati o PbO : PbSOr; and i n
,

adm i xi ng 50 per cent pyr i te thi s r ati o was ch anged to 2 PbO : 3PbSO .
. The .

presence of other sulphi des i s li kely to i ncrease the amount of PbSO . formed .

Th e study of B anni ster of the eflects of gangue m

1
i nerals i s of speci al i nte rest .

The gale na concentrate wi th wh i ch he carri ed on m ufli e roasts co ntai ned Pb -

8 8103 Fe Zn
p er c ent Fi g 33 gi ves the temper ature
. .

record of a roast of galena mi xed wi th

2 0 per cent li me The dotted li ne CD
. .

rep resents a blank test the full drawn

m
-

li ne AB the charged mu e C urve AB .

shows a sli gh t evol uti o n of h eat between

° °
1 80 and 2 60 C due to the o xi dati on .
,
°
of a sm all amou nt of py i te ; at 560 a
r
consi derable ri se i n temper at ure takes

place accompani ed by a glowi ng of the

charge ; th e evoluti o n of h eat ceases after

but i s followed by a second ri se

°
at 74 5 whi ch i s not sufli ci ent to cau se

a glo w
m 15 so 25 so 85 40
°
; at 800 a th i r d ri se occurs whi ch 0 5
0 111mm
ca use s the charge to glow and the te m
m
1

M u e roast galena— li m e m
FI G 33 — i xture 0
p era t ure to ri se rap i dly to 9 00 T h e .
. .
-

, .

first evol u ti on of h eat now shown to ,

take place at was noti ced by Percy and by H utchi ngs The composi ti on
1 1
.

of the charge afte r th e fir st glow h ad ch anged f rom PbS

, CaO ,

$ 102 N D per cent to PbS

. . PbSO. Pho CaO .

CaSO . $ 103 N D p er ce n t ; an d afte r th e se co nd. g low .to P bS .

ni t PbSO . ni t PbO
, CaO CaSO . , 8102 N D per cent . . .

The first analysi s shows that du ri ng th e first glow some PbS has bee n
co nver t ed i nto PbSO . and a co nsi der ab le amou nt i nto PbO also th at some
, ,

1
Loc . ci t
.

1
Tr I nsti l
. . Mi n Met , . 1 91 —
2 1 3 , xxx, 34 6 .

1 “Lead " 2 38.

p .

1
E ng . Mi n . J 1 905, x
x xx , 72 6 .
44 ME TALLURGY OF LE AD

CaSO. has been formed ; the second that the remai ni ng PbS and PbSO. have ,

been conver ted i nto PbO and the whole of th e re m ai ni ng S i s pre

, s ent

as CaSO . This proves that CaO has a decomposi ng efl ect upon PbS i n
.

an oxi di zi ng roast ; a fact i nti mated by Ri vot and clai m ed also for BaO
1
.
,

Fi g 34 gi v es the temper ature curve for a mi xture of galena wi th 2 0 p er cent

.
-
.

8103 havi ng the compo si ti on Pb Sfog ND per cent Betw een . . .

1 80 and 2 90 there i s ag ai n a sli ght evol uti on of heat due to the pyri te present ;
°

the fi rst ri se i n temperatu re due to the oxi dati on of PbS occurs at 53 the
seco nd at and the thi rd at The first two evol uti ons take place
at temp eratur es sli gh tly lower th e thi rd ,

at a sli gh tl y hi gher temperature th an

do those noted wi th the li me m i xture ; -

all three evoluti o ns are le ss i ntense .

Afte r heati ng to 700 the composi ti on

°

of the charge has changed to PbS

PbSO. PbO $ 103 N D
. .

°
p er c n e t .
; and a fter 850 to PbS
PhSO. PbO 8103
per cent A compari son of N D . . .

the composi ti ons of the p roducts of the

— —
PbS C ao and the PbS Si Og mi xtures
sho w s that at these roasti ng temper a
5 1° 15 2° 11 1 ° 1“ 1° tures CaO acts very difl erently from
FI G 34
.
— . m
Mu e roast galena sili ca m
— ixture
-
510 3
,
the latter servi ng only as a di l ue nt

of the charge Practi cal experi ence

.
,

wi th blast roas ti ng has brought out the fact th at charges wi th an admi xture
of CaO work better than those havi ng other diluents
I n the ori gi nal p aper Banni ster gi ves curves for m
m
ix tures of Pbs wi th PbO
,

CaO wi th CaC03 CaSO I MgO

, o. and CaO + H , O
, Th e research of
, , .

Percy upon the changes galena undergoes i n the E ngli sh reverb eratory
1

furnace supplements the laboratory work of Banni ster .

The decomposi ti on of PbS by a metal whi ch has a stronger afi ni ty for S

than Pb studi ed i n 1 833 by Fo urnet has been rei nvesti gated by Schli tz who
,
1 1

places the metals

M n Cu Ni Fe Sn—Zn—Pb
— — — -

in the gi ven order M n for m i ng the strongest and Pb the w

, eak e s t sul

p hi de I n t
.he smel ti ng of l ea d or es M n need not be co nsi dered as i t pr ac ti cally ,

al ways occurs as M n0 whi ch enters the slag and i s fou nd o nly to a very small
, ,

extent i n m atte Of the other metals Fe i s the most i mportant ; the reacti on
.
,

PbS + Fe = Pb+ FeS forms the bas i s of what i s called the Preci pi tati on Pr oces s .

“Trai t
1
é de Metallurgi e, ”
D unod Pari s, 1 87 2 , II , p.
4 2 .

“Lead ” 2 —2 0
,

1
, 34 4 .

1
Hofman ,
“General Metallur
gy, 1 9 1 8, 74 .

11 6101110 1 16 . 1 90 7. N .
659. 694 .
 LE AD COMP O UN DS 45

Practi cal experi ence has shown that the decomposi ti on of Pbs i s never complete ;
and Sch il tz has proved that the r eacti on M S + N = M + N S i s i n p art

reversi ble In f urnace work i t is customary to calculate the Fe necessary for

.

t he decomposi ti on of Pbs accordi ng to th e formula gi ven: if less Fe i s added ,

th e r esulti ng m atte remai ns too ri ch i n Pb ; if an excess i s gi ven i t i s wasted , ,

as the Fe i s si mply di ssolved by the PbS FeS matte — The amou nt of Fe the .

matte ean hold in soluti on vari es wi th the te mperature The alloy seri es .

—
FeS Fe has been studi ed by Fri e dri ch 1 —
the seri es FeS Fe PbS awai ts —
,

i nves ti gati on An excess of Fe i n the charge m

. ay be di sadvantageou s i n the

deco m p o s i ti o n of a rge n ti fe rou s g a l e na si nc e o n a c c ou n t of t h e a fi ni ty o f

Ag¢ S and FeS (see Matte § x80) more Ag wi ll go i nto the m
,

atte than can be ,

accounted for by the amou nt of Pb pr esent In ad di ti on to havi ng the correct .

amount of Fe pre s e nt to decompo se PbS the temperature of the reacti o n i s of ,

deci ded i m p o rta nce ; the hi g h er i t i s w i thi n r e a s o n a b le li m i ts the better w ill , ,

be the decomposi ti on A basi c ferrous sili cate . will decompose

PbS rea dily ; the si ngu lo sili cate ( 2 FeO Si O g) shows li ttle efl ect In pr acti ce
-
. .
,

the amount of Fe i n excess of that req ui red to flux the $103 i s available for the
decomposi ti on of PbS .

Accordi ng to B erthi er CaO and BaO have a decomposi ng cflect upon Pbs
1
, ,

if air i s excluded and C pres ent :

The research of Schli tz shows th at the prese nce of Ca i n a ch arge greatly
1 S

di m i ni shes the yi eld of Pb and that the har m ful eflect of BaS while si milar i s , , ,

very much weaker .

4 0 Lead Sulph ate, Ph SO .

. per cent Pb; 2 07Pb+ 32 S+ 64 O .

0
3 3 P b S O . + 2 1 57 00 — T hi s o c c u rs a s
, an g l es i te ; i s f or m ed i n ro as ti ng Pb S
The m
°
and i n p reci p i tati ng lead sal ts wi th H zSO I elti ng poi nt li es above 1 1 00 .
-

C but i s di fi cul t to determi ne on account of dissoci ati o n (see b elow)

.
,
It i s a .

poor conductor of electri ci ty ; i s sli gh tly soluble i n H gO les s so i n dilute

1
,

H gSO . ; somewh at soluble i n concentrated H , SO i n H N O ; and sol uti o ns of

ni trate s i n hot H Cl ; in solut i ons of N agSgO g the solubi li ty i ncreasing
, ,

wi th concentrati on and te m perature i n CaClg Nacl C8 ( C3H 303) 3 and “

, , ,

N H r salts .

Pb8 04 is decomposed inpart by heati ng The consti tuti onal di agram .

PbSO I PbO by Schenck Rassbach i s gi ven i n Fi g 35

- "
I t show s the exi ste nce -
. .

of two stable basi c sulphates PbSO . PbO wi th p er c e n t Pho an d P b SO . ,

. .
, .

2 PbO wi t h per cent PbO ; a thi rd basi c sulphate PbSO. 3PbO wi th .

,
.
,

p er c ent P ho i s sta b le o nly bel ow as i t

. sp li ts a bove th i s tempe
, ra

ture into PbSO. 2 PbO and PbO There are also three eutecti c m . i xtures .
,

1
Hofman ,
“General Metallur
gy, 21 3 .

“ ” “Lead ”
1
Trai té des E ssais, etc . 11, p 6 73 ;
. also Percy, , 55
.

1 Loc cit .

1
Ki li ani , Berg H rl ttenmZ . . .
, 1 883 , 2 35, 375 .

Stet efeldt, C A , The Li xi vi ati on of Silver Ores w

1 . i th Hyp osulphi t e Soluti ons,
.
”
New
York , 1 89 5, 2 5 .

1
Met Che Eng , 1 9 1 6, XIV, 3 1 m . . .

1
B er dentsch che . . m
Gesell , 1 907, XL, 2 1 85, 2 94 7 ; 1 908, xxx, 2 9 1 7 . . .
46 ME TALLURG Y OF LE AD
—
PbO PbSO. wi th 87 p er cent Pho freezi ng at
PbO —
PbSO. 2 Pho PbSO.
.
3 .
, . .

PbO wi th 53 per cent PbO freezi ng at —

and PbS O I P bO P bS O. wi th .
,
°
30 p er ce nt P b O free z i ng at
.
950 C I n the so li d s ta,
te t he re a r e two .

transform ati ons one of pure PbSO . at ,

the other of PbSO. 2 PbO .

In heati ng Pb804 i n a current of ai r Doeltz Graum —

°
ann fou nd
1
at 4 50 C .
,
°
di ssoci ati on to begi n at 900 C and to i ncrease to 4 6 p er cent by heati ng .
,
.

1 5 hr at
. . H ofman Wanjukow found that i n a current of ai r PbSO .
— 1

°
sh ows the first si gns of di ssoci ati on at 63 7 and th at energeti c decompo si ti o n

begi ns at 705 wi th the form ati on of

°

n ] P C nt Peso 1
1m
o er e

90 w70 go 50 go 3° 2° 10 o 0 0 l t u goe
d
.

b h i
,
6 P 5$ 3 T s sa n e r s 3 11 3 11 3 . . .
"

formati on at begi ns to be decom

po sed at to si nter at and to

fuse at rapi d discsci ati on i nto

and i s acco m
°
2 PbO SOa beg i ns at 9 52 .

p an i ed by vo la ti li z a ti o n of Pb O T h e .

later i nvesti gati on of M ostow i tsch sh ows

1

0 10 2080 0 50 00 70 1 1 90 100
t h at p arti al di ssoci ati on beg i ns onl y at

MOI P c nt PbO that the speed of decomposi ti on i s

. er e .

Cons ti tut i onal di agram

°
FIG 3 5
.
— .
8 10W uP to 9 50 and qu i ck wh en the temper

PbSO c PbO ature i s rai sed above 9

-
. that f usi o n
° °
occurs between 950 and 1 000 after a
p ar ti al decomposi ti o n of the no rmal PbSO . .

$ 102 rea di ly decomposes P hso 4 at C formi ng lead si li cate wh ile

1
.
,

the SO; dr i ven ofl i s spli t i nto SO , and 0 “

Mostowi tsch has shown that i n .

the pr esence of $ 103 the di ssoci ati on temperature i s not lowered ; that th e
decomposi ng eflect of $ 102 is not proporti onal to the amount present but ,

rather that the reverse holds true as decomposi ti o n is governed by the vi sco si ty ,

of lead sili cates formed th e viscous slag e nvelop ing PbSO. and retardi ng ,

the deco m po si ng acti o n; and that the most rapi d decomp osi ti on accompani ed
by the lowest lo ss of lead by volatili zati on li es between the si ngulo and bi
sili cate co ntai ni ng from 1 0 to 1 5 per ce nt 8103 . .

The PbSO. obtai ned i n roasti ng a sili ceous gale na is th us decomposed if ,

the temperature i s suffi ci ently raised and the percentage of $ 10: correctl y
apporti o ned The Oper ati o n goes by the name of S lag roasti ng
.
-
.

FezO . also has a decomposi ng eflect “

Proske found th at i t assi sts decom .

posi ti on at 900 C and hi gher tempe rature s that i ts acti on i s less energeti c
°
.
,

th an that of $ 103 and th at at 1 1 00 the e nti r e SO; i s dri ven ofl

°
,
H e also .

found that P8 20; heate d to r2 oo i s a more powerfu l decomposi ng agent °

th an the ordi nary red oxi de H e f urther ascertai ned that if FeO i n contact -

1
Metallnrgi e, 1 906 m, 44 , .

1
Tr A I M B 1 9 1 2 x u n, 5 2 3
. . . . .
, , .

1 Tr A I
. M E 1 9 1 6 LV, 74 1 ; Met
. . . .
, ,
. Che m E ng . .
, 1 9 1 6, xv, 46 .

1 Fri edri ch , S tahl n E i sen, . 1 91 1 ,

xxxx, 2 04 0 .

5 LOG . Gi l .

M etall . n E re
. .
, 1 9 1 3, x , 4 1 5; E ng . Mi n . J .
,
1 9 1 3, x cvI , 2 0 7 .
48 ME TALLURGY OF LEAD

possi ble by the interacti o n of Pb PbS PbO PbSOI and $ 03 Under the ,
.
, , , .

gui dance of the phase rule they m ay be grouped to form fo ur eq uati ons .

( )
a T hi s e q ua ti o n i s reve rs i b le E qu ili b ri a were .

found at 69 2 C wi th a tensi on of $ 0: of 6 m
°
. m H g ; at 755 wi th 38 mm; at . .
°
.

800 wi th 99 mm ; at 84 7 wi th 544 m m; at 870 wi th 830 mm The acti on of

° °
. . .

—
PbS upon PbO begins at 650 660 C and becomes very deci ded at 700 at
° °
.
°

800 PbS begi ns to becom

°
e volatile and the volatili zati on i ncreases rap i dly ,

wi th the temperature .

( )
6 T hi s equ a ti o n i s a ls o r ever si ble E qui .

li bri a were found at 609 C wi th a tensi on of SO, of 30 m mH g ; at 655 wi th

° °
. . .

1 55 mm ; at 700 wi th 4 2 2 m m; at 72 3 wi th 735 mm The acti on of PbS

° °
. . .

°
upon PbSO. begins at 550 C and i ncreases i n veloci ty wi th the temperature .
,

but is governed by the pres sure of

( )
c a n d ( )
d P b S + 3Pb SO . >
4 Pb O + 4S O g a n d P b+ P b S O .
-

The equati ons show no eq ui li bri a even up to a pres sur e of SO: of 760
mm H g The components begin to act at 550 C and the reacti ons proceed
. .
°
.
,

from left to ri ght i rreversi bly .

It w i ll be no ti ced that the reacti ons were stu di ed under pres sures of pure
SO; rangi ng from 6 to 830 mm H g In f urnace practi ce there i s no pressure of . .

803 ; on the contrary there i s a sli gh t vacuu mdue to draft In a furnace .

charge also one has to deal not wi th pure $ 03 as i n the experi ments but wi th
, , ,

ai r charged wi th sm all amo unts not over 7 per cent of CO3 and 803 the p arti al , .
, ,

pressure of whi ch i s low Lastly 803 the gaseous phase bei ng wi th drawn .
, , ,

from the furnace as soon as formed we have to deal wi th three i nstead of four ,

components ; he nce th e presupposed equi li bri a and reversi ble reacti ons have no

exi stence and equati o ns (a) and (b) i n furnace work proceed only in one the
,
-

usual di recti on from left to ri ght As to reacti on (c) wi th reference to blas t .

roasti ng the forced draft carri es ofi the SO, set free as soo n as formed ,

and th us assi sts i n the qui ckness of the roast b esi des i ncreasi ng the tempera

ture both of whi ch favor an accelerati on of the process .

Accordi ng to Re i nders Pbs acti ng upon PbSO. form

1
, s the basi c sulpha te

4 P bO P b .O w
S . hi c ac ih t ng up o n P bS li ber a te s Pb vi a P b S+ 7 Pb S O r
= 4 PbO .
, ,

PbSO4 + 4 SOg and 6 PbS + 4 PbO PbSOI = 1 4 Pb+ 1 0803 If the two equati ons
. .

are added and the i ntermedi ary product i s omi tted there i s obtai ned 7PbS +
, ,

7 P b S O = I 4 Pb + 80 or PbS + P b S O 2 P b + 2 $ 03
. 1 4 2 . ,
.

1
Zt . anorg . Che m .
,
1 91 5, xxx
xx, 2 1 E
3 ; ng . Mi n J . 1 91 6, 011 , 8 70 .
 CH APTE R VI

LEAD ORES

4 2 . Many mi nerals contai n lead but only two or three are

Introducti on — .
,

found i n sufi ci ent quanti ty to be consi dered as i mportant source s of lead .

Accordi ng to the character of the lead mi neral the ore s of lead are di vi ded i nto ,

the two classes of sulph i de ores (g alena) and oxi de ores ( anglesi te cerussi te etc ) , ,
.

comm onl y called carbo nate ores ; both are m ade mo re or le ss i mpure by other

metac compounds and forei gn matter Vi ewi ng ores from the manner i n
°
.

whi ch they are to be fluxed i n the blast furnace they are classed as sili ceous , ,

basi c and neu tral ore s acco rding as they requi re a base or sili ca or are self
, , ,

fluxi ng; relati ve to the ne ce ssi ty or desi r ab i li ty of eli m i nati ng mo st of the S

before smelti ng they are consi dered as roasti ng or non roasti ng ores practi cal
,
-

desi gnat i ons whi ch are i n mo st case s synonym ou s wi th the terms of sulphi de
and oxi de ores .

43 Le a
.d M i nerals — Galena (P bS ; p e r cent Pb per c ent S ) .
, . .

Thi s mi neral i s found well cry stalli z ed i n cube s someti mes also i n i sometri c -

octahedrons Crystals are not so often fou nd i solated as i n i rregular bunches

. .

I t occurs also i n coarsely crystalli ne to fine granular vari eti e s ; crypto crystall i ne -

gale na i s rare Galena i s found i n most of the geologi cal formati ons It i s
. .

usuall y mix ed w i th more or less vei n m atter su ch as li me stone dolom i te sand , , ,

stone quartz earthy carbo nates b ari te clay slate grani te g nei ss etc
, , whi ch , ,
-

, , , .
,

Often have to be removed by a me chani cal wash i ng pro ce ss before send i ng th e

mi ne ral to the smeltery The m i ne whi ch wo rk s on the lowest grade gale na ore
.

i s probably that at M e cherni ch Rh eni sh Pru ssia where sm all nodule s of galena , ,

the si z e of a p ea occur i n a soft Tri assi c sandstone the grai ns of whi ch about , ,

the siz e of millet are sli gh tly cemented by a clay or li me bond Th e ore con
, .

tai ns only 2 5 per cent of galena and the galena runs only about 6 oz silver p er
. .
,
.

ton .

Table hows the 10 s some known galena rock s and formati ons i n whi ch well -

deposi ts occur and the tenor of the ore befo re and after dressi ng .

In Tab les 1 1 and 1 2 are assemb led anal yse s of galena conce ntrates from
Southeast M i ssouri .

The average lead content of the sulphi de lead ores mi ned i n the U S i n . .

1 91 4 w e t th t of l e d i ore per e t
1
as p er c n a a z nc s c n .
,
-
.

1
Mi n . Res U S
. . .
, 1 91 4 , I, 4 2 3 .
50 ME TALLURGY OF LE AD

T AB LE Io
— . SU LPH I DE LE AD ORE S

Raw D ressed O re
o re,

Locali ty Geologi cal formati on per Per

cent .
cent .

Pb pb

Mi neral Poi nt, W i s Ordo vi ci an

Rock ville, W i s Ordovi ci an
Granby, Mo Lo wer Carboni ferous .

St Josep h, Mo
. Ca mbri an
North of E ngland Carboniferous
Blei berg, Cari nthi a
Pii bra m Bohemi a
,
G raywacke . . Lo wer Siluri an

Frei berg, Saxony Gneiss . Arch m .

w
Tarno i tz , Silesi a Triassi c
Up per Harz ,
Graywacke Lower Carboni ferous .

sla te

Mecherni ch , Prussia Sandstone 2 56 —60

3
—
4
Kellogg, I daho 1 1 60

1 . G eol ogi cal Survey of W i sco nsi n. 1 8 73 -

79 . IV . 3 8 2 .

2. Desl oge. Tr A I M B , 1 88 9 9 0.
. . . .
-
x vxrr. 2 6 2 .

3 . H unt R .
“
B ri t i s h Mi ni ng . Crosby Loc kw ood Lo nd o n. 1 8 8 4 899
Co .
, . .

h p
P i lli s. J A . . ,
“
E le ments Of M etallurgy .
"
Li pp i ncott P i ladel , h ph
i a 1 8 8 7 . 566 . .

Oesterr Z t B erg c
4 a 1 89 0. xxxvur 2 86

mm
. . . . . .

s I bi l . 1 88 8 xxxvx 56 7 ; and Oest err J ohrb . 1 89 1 .

. . . . 10 . . . .

“
6 Frei berg B erg und H uttenweeen
"
Craz and G erlac . Frei berg . h 1 883. 83
mm
. . .
.

7 Zt B erg H utton S al W i Pr 1 8 84
. . . 39 2 . . . . . .

8 I bi d 1 8 80 xxx 1 3 1 and Pri vate notes 1 89 0

. . . . . . .

“
9 B erg bau und H ut tenbet ri eb von
. ec erni c Cologne. 1 886 M h h , .

1 0 Pri vat e notes

. .

TAB LE I L — AN ALYS ES or GALE N A CO NCE NTRATES rnon SournE As r '

Mi ssounr

T AB LE 1 2 .
— AN ALYSE S or ORE S AS MINE D IN SournE Asr s so unx AND or V ARI O US G RAD E S
or RE S U LTI N G CO N CE N TRATE S ( a)

0 1 2 0 06 5 7 5 0 4 9 25 5 14 2 0 8 2 0

Hi gh -

grade 0 7 0 I 3 73 2 1 0 2 6 0 8 0 4 1 5
Medi umconcentrates r 3 0 I 2 68 6 I 4 3 x 1 4 0 8 1 5
Lowgrade -
I 0 0 30 5 65 8 0 4 3 2 8 1 7 I 3 7
Flotati on sli mes 50 4 5 0 9 6 7 5 4 2 4 0 1 2 3
Flota ti on s li mes , hi gh grade 3 7 -
0 O 5 57 8 6 O 2 2 I 4 9 4 I 5 5
Jopli n concent rates 2 1 x 0 4 I 7 13 3

( a) G arli chs A B all A l . . . . M . E J uly . 1 9 1 7 . 1 043 .

( 5) Ounces p er ton .
 LE AD ORE S 51

Galena often o ccur s in a ve ry pure state but i s more generally mi xe d wi th ,

o ther metalli c sulph i des These are ei ther pyr i te arsenopyri te chalcopyri te .
, , ,

blende bournoni te j amesoni te etc whi ch occur as associ ated mi nerals; or

,
1
, ,
.
,

si l ver copper zinc i ron ni cke l etc whi ch form ch em

, , ,
i cal compounds wi th the
, ,
.
,

lead sulphi de The asso ci ated mi nerals can usually be separated mechani cally
.

from th e gal ena but not always Someti mes the admi x ture i s too inti ms te
, .
,

and th en cause s trouble and loss i n the metall urgi cal treatme nt .

Gal ena i s almost always argenti ferou s The silver i s rarely present i n the .

nati ve state ; i n galena poor i n si lver i t m ay appear as i somorphou s silver sul ,

p hi d e but ,
a mo r e c ommo n mode of o cc urre n c e i s a s a fi n e ly d i ss em i n a ted a r ge n
t i te or o th er r i ch silver m i neral N i ssen and H oyt found that the li m i t of soli d
1
.

soluti o n of An i n PbS i s per cent and tha t the eutecti c i s not developed .

i n conce ntra ti o ns b elow p e r ce n t T h e difl er e nc e of form i s i mport a n t i n .

connecti on wi th wet concentrat i o n If the si lver occurs as i somorphou s sul .

p hi de the ,
loss i n co n ce nt r a t i o n w i ll corre spo n d appro x i m a te ly to the per c e n t , ,

age of lea d i n the tailing ; if as associ ated mi ne ral e g tetrahedri te i t wi ll be ,

. .
, ,

great as thi s mi neral be i ng very b ri ttle i s readi ly cru shed to a fine powder
, , , ,

and be i ng also li gh ter than galena i s carr i ed ofl on the water

,
If the dark scum ,
.

tha t i s often seen floating on the water of j i gs treati ng argenti ferous galena be
assayed the m ai n sour ce of lo ss i n silve r wi ll appear
,
.

T he tenor of si lver i n galena o re s vari es a great deal The galena from .

Blei berg C ari nthi a wi th , 5 o z s i lve r p er to n repre , s e n t s prob a b ly t h e lowe s t .

,

amou nt and occasi onal speci mens from Idaho and Schem ni tz H ungary w
,
i th , ,

oz the hi gh e st . .

I t has often been sai d and m ay someti me s sti ll be heard that coar se grai ned , ,
-

g a le n a i s poor i n sil ve r w h e r ea s fi n e g ran u la r v a ri eti e s g i ve

,
h i g h er as sa y s ; but
Malagu ti and Durocher di sproved i t over si xty years ago The mi nerals
1
.

usually asso ci ated wi th galena su ch as pyri te blende etc do not generally

— — .
, ,

contai n as mu ch si lver as the galena .

P ercy states that gold i s as i nvari ably pres ent i n galena as i s si lver but i t
1
,

does not often occur i n appreci able quanti ti es N evins r “ ecords th e occur .

rence of a gale na ore i n So no ra wi th oz Ag and oz Au p er ton i n the . .

,

co nce nt rate of wh i ch no nat i ve gold cou ld be fou nd wi th the mi cro scope .

Metallog raphi c methods however mi gh t have di scovered i t , ,

.

Anglesi te ( PbSO 4 ; PbO 803 Pb per cent ) ; Cerussi te , , ,

( P b C 03 ; P b O C 0 2 Pb ,
per —
C a rbo na te ore ,
s u si n g th a t , ,

te rm i n a general te chni cal se nse as embraci ng all oxi de lead ore s occur often i n ,

th e form of a sand or an ear th bearing the name of sand or soft carbonates In ,

.

1
S mlti ng of
e : I ves—
Ossa .
,
E ng . Mi n . J .
, 1 909, Lxx xvxx, 89 1 .

Holi n M et ,
Che m E ng
. .
, 1 9 1 0, VII I , 686 .

Ray mond , E ng . Mi n . J 1 91 5, x cxx, 9 .

1
Econ Geol . .
, 1 9 1 5, D1 , 1 72 .

1 Ann . Mi n , . 1 850, XVII , 85 .

“ ”
4 L ead , 96 .

1 Eng . Mi n J . .
, 1 905, 769 .
52 ME TALLURGY OF LEAD

other cases the parti cles of carbonate are cemented together by clay i ro n man , ,

ganese or sili ci ous matter form

,
i ng compact amorphou s or cry stalli ne lump s
,

called hard carbonates .

The m i nerals are seldom found as Ori gi nall y depo si ted ; the form and compo
si ti on are mo re li kely to have been cau sed by chemi cal change s that have taken

place since the galena from whi ch they resulted was depo si ted The sulp hate
, , .

usually fo rmed by the oxi dati on of the sulphi de i s i n most cases the compou nd
from wh i ch the carbonate has resulted by the acti on of ci rculati ng waters hold
i ng alk ali ne or earthy carbonates i n so luti on .

Angle si te as an ore i s rare as i t i s not often that galena i s expo sed only to
,

th e oxi di z i ng acti on of ai r I t often occurs however wi th ceru ssi te and rep re

.
, ,

sents the transi ti o n betwee n the sulp hide and the carbo nate Thi s i s further .

illu strated by pi e ce s of galena found i n carbonate o re s whi ch co ntai n a rind of ,

anglesi te wi th a surface changed to cerussi te Th us these two m i ne rals w ill be .

found always near the outcrop s of galena deposi ts To what extent th e decom .

posi ti on has progressed depends on local ci rcumstances .

The ri chne ss i n lead of carbo nate o res vari es a grea t deal If galena al one .

has bee n oxi d i zed th e ore s are li kely to be ri ch ; if the decompo si ng acti on at
,

tacked also the cou ntry ro ck thi s may contami nate the ore to su ch an ex tent as
,

to reduce the percentage of lead below the li mi t where i t pay s to trea t the ore .

The grade of carbonate ore i s not so ofte n rai sed by wet conce ntrati o n as that of
galena ore as the lo sses i n lead and especi ally i n silver whi ch passe s ofl i n th e
, , ,

sli mes are almost u navo i dab le

,
In some i nstance s the carbonate ore has bee n
.

first leached wi th sod i um hypo sulphi te to remove as mu ch si lver as po ssi ble ,

and then th e lead co ncent rated i n th e wet w ay to a ri ch produ ct Th i s w as .

fo rmerly done at the Old Telegraph Mi ne Utah Another method that has ,
.

been tri ed i s Kroms system of dry concentrati on the result bei ng a hi gh grade
’
,
-

sme l ti ng ore and a taili ng and dust to be t rea ted i n th e wet w

, ay ,Tab le .

1 3 shows some very pure carbo nate o res from M i ssouri resul ti ng from co rre

spondi ng ly pure galena and others f rom Co lorado contam i nated wi th cou nt ry
, ,

rock Mo re recent analyses of carbo na te ore are gi ven later

. .

T AB LE I3 —.CAnB ON A rE
'
LE AD 02 3 5

Local i ty Reference

South -
W estern Mi ssouri . Chauvenet B roadhead, Geologi cal Survey
of Missoum, 1 8 74 7 1 0 , .

Granby Mo W illi ams Tr A I M E 1 876 77, v, 3 1 5

—
A I M E 1 885 86 m 2 87
. . . . . .
,
.
,

Leadville, Colo . Ri ck et ts Tr
. .
—
. . .
, , ,
.

Leadville, Colo . Rolk er Tr

. A I M E , 1 88 5 86 xxv 2 87
.
—
. . .
, , .

Red Mountai n, Colo Kedzi e Tr

. A I M E. 1 —
887 88 xvx 58 1
. . .
, , ,
.

The o ted mi nerals unde rgo a process of oxi dati on wi th the galena and
ass ci a

are generally fou nd ag ai n i n p art i n th e carbo na te ore al th ough bei ng more , ,

 LE AD ORE S 53

sol uble the lead sulphate they m

than ay have been carri ed away entirely , .

The silver i n oxi di zed ores i s pre sent mostly i n the form of chlori de (Lead
ville chl orobromi de bromi de ; and B roken H ill i odi de) al though i t also occur s i n ,

i ts ori gi nal form as sulphi de and anti moni de or arseni de Th ere i s le ss li keli hood .

of a uni form rati o between lead and silver i n a carbonate ore than there i s i n a
sulphi de ore as lead su lphate and carbonate show a behavi or wi th solvents
,

di fi erent from that of silver su lphi de chlori de and antim oni de Th us , , .

enri chment and i mpoverishment both i n lead and silver can be accounted for
easi ly .

45 O th
. er L ead M i neral s — Th e fo llow i ng si x o xi de lea d m i ner a ls occur

often i n carbonate deposi ts but not i n sufli ci ent amounts to consti tute an ore : ,

Pyromorphi te per cent Pb C alci um fluori de

,
. .

often replaces in part the lead chlori de ; calci um tak es the place of th e lead com
bi ned w i th phosphori c aci d ; and ar seni c aci d that of the pho sphori c aci d .

M i meti te PbClg+ 3s AszO s; per cent Pb I n the lead arsenate the

, . .

lead i s someti m es i n part replaced by cal ci um and the arseni c u sually i n part ,

by p ho sphoru s .

Vanadi ni te PbClg+ 3s V,Os ; 65 per cent Pb 1

,
. .

Cro co i te PbCrO . ; per cent Pb,

. .

W u lfeni te PbM04 ; 57 per cent Pb ,

. .

S tolz i te PbW 4 ; per cent Pb

,
. .

There mi gh t still be menti oned about 2 0 lead beari ng sulp harseni tes sul -

p hanti m ni tes o ,
and sulp hobi s muthi tes ,
1
sulp hoarsena tes, sulp hanti rnonates,
1

etc . whi ch occur i n lead

only mi neralogi cal curi osi ti es deposi ts but they ,
are .
1

6 L e ad O of th e Un i t ed S ta tes — Lea d o e o ur i n m ny p rt of th
4 . res r s cc a a s e .

wor ld The mines of Spai n and Germany furni sh the bulk of the E uropean
.

product but i t i s not the present p urpo se to deal wi th that branch of the
,

subje ct .

The o ccurre nce of lead ores i n the Uni ted States i s best di scussed under four
heads : The Atlanti c Coast ; the M i ssi ssi ppi Valley ; the Rocky Mountai ns;
and the P acific Coast .

47 A tl
.an ti c C oa st — Th e le ad o res of th e A tla n ti c coast occur i n N ewYork ,

N ewE ngland Vi rgi ni a N orth Caroli na and Tennessee Tho se of N ewYork

, , , .

and N ewE ngland whi ch were wo rked i n former ti mes are p racti call y aban , ,

doued now and those of the Southern States are worke d only on a small scal e
,
.

Virgi ni a has some depo si ts of galena and ble nde wi th carbonate and si li cate
of zi nc; the lead however i s subordi nate to the zi nc , ,
.

1
T reat mnt e : H errensch mi dt , m
Co pt . rend .
, 1 904 , cxx mx , 63 5; Oesterr. Zt . Berg .

H tllt enw, . 1 905, L111 , 201 .

Larsh , E ng Mi n J , 1 9 1 1 , x c1 , 1 2 48 ; 1 9 1 3, x cvx, 1 1 03
. . . .

G rider, M i n S c Press, 1 9 1 6, cxxxx, 389 . . .

1
Treat m ent : Bretherton, E ng M i n J , 1 9 1 0. 1 xxx r x , 773 . . . . .

1 Treat ment : I ves Ossa -

.
, Eng . Mi n . J 1 909 , Lxxxvrx, 89 1 .

Hahn Met , Che m E ng . .

, 1 9 1 0, VI II , 686 .

Ray mond Mi n J 1 9 1 5 x crx 9

, E ng . .
, , .

1 Dana , Systemof Mi neralogy Wiley

”
, , NewYork, 1 898 , 1 09 —1
51 .
54 ME TALLURG Y OF LEAD

4 8 . hi s h eadi ng covers two di vi si o ns : the lead regi o n

Mi ssi ssippi Valley .
l —T

of the Upper M i ssi ssi pp i Valley and that of Mi sso uri .

Lead ore i s mi ned in Oklahoma Kansas and Kentu cky but the output i s , , ,

sm all .

Upper Mi ssi ssi ppi Valley In the southwestern part of Wi sconsi n occur
—

the lead deposi ts whi ch extend a small di stance i nto the adjoi ni ng S tates of
I owa and Illi noi s They are pri nci pally ce ntered around M i neral Po i nt and
.

P la ttevi ll e Wi s Galena , and D ubuque , Iowa

. M ost of the lead produced , .

comes from Wi sco nsi n .

Th e ore i s a non argenti ferous galena ; i t occur s i n wholly u ndi sturbed do lo

-

mi ti c li mestone of the Trenton peri od i n verti cal crevi ces flat crevi ces or as an , ,

i mp regnati on The galena . from the upper beds i s pure and ri ch .

As depth i s g ai ned the associ ated mi ne rals marcasi te and blende i ncrease i n
,

quant i ty and often predomi nate over the galena Chalcopyri te i s scarce .
,

and i s found more wi th pyr i te and blende than wi th galena Secondary m i nerals .

are not of frequent occurre nce C alci te and bari te occur i n the lower beds . .

The ab sence of ni ckel cobalt and arse ni c i s to be noted , , .

Mi nes of Mi ssouri fi In both the southeastern and the sou thwestern di s

—

tri cts the ore i s a coarse ly cry stalli ne galena p racti cally free from si lver , .

I n the south eastern di stri ct galena occur s di ssemi nated through strata ,

of dolomi ti c li me stone of the Cambri an lyi ng almost hori zontally The ore as , .

mined runs about 3 5 per cent Pb and i s concentrated to a product of 67 per . .

cent Pb An analysi s of a carload of concentr ate from the Bon e T erre and
'
.

Fla t Ri ver di s tri cts gave Pb Cu Fe C3 0 MgO

Slog per cent and Ag oz per ton Th e rati o between CaO and MgO
. . .

appear s frequently to be about O ther analyse s have been gi ven i n

Tables 1 1 and 1 2 .

Associ ated w i th the gal ena occurs pyri te contai ni ng ni ckel and cobalt .

Chalcopyri te and ni ckel and cobal t sulphi des wi th traces of arseni c are found
i n the Mi ne La Motte and Bon e Terre mi ne s Th e ab sence of b lende i s to .

be noted T he pyri te beari ng galena ore s are concentrated separately from

.
-

”
the p ure galena to a product call ed su lphi de whi ch has the composi ti on ,

gi ven i n Table 1 4 .

T AB LE 14 — Surna . me CONCE NTRATE or SOU THE AS TE RN Mrssomu

Che mi t
s

‘
V H ise C an , . R
“
.
, Bai n, H . F .
, M i n E ng
Tr I ns t . . . .
,
—
1 90 1 1 90 2 , xx m 37
,
—
0 4 34 .

‘
W i nslow A , .
, Lead and Zi nc D eposi ts, M i ssouri G eologi cal S urvey, J efi erson Ci t y,
1 894
mcxxv 6
.

Fi nlay, E ng M in J 1 908 , 1, 0 5.

mm 58
.
. .
,
‘
E di tor, E ng . Mi n J . .
, 1 90 2 , o , 2.
56 ME TALLURGY OF LEAD

Colorado .
—The
depo si ts of argenti ferous lead ores of Colorado used to be
the most i mportant of the country but the p ro ducti on of the S tate has f allen ,

ofi greatly fur ni shi ng i n 1 9 1 5 o nly

,
tons of lead .

Th e San Ju an reg i o n si tu ated i n the south western part of the S tate i s

, ,

char acteri z ed by i mm ense quartz vei ns traversi ng older and younger erupti ve
rocks In the nei gh bor hood of Ri co ( Dolores County) o ccur silver lead ores
.

mai nly i n the form of blankets between carboni ferous li mestone and erupti ve
rocks ; i n the Red M ountai n di stri ct (Ouray County) deposi ts are found filli ng
cavi ti e s i n si li ci fied ande si te The m i nerals are arge ntiferous gal ena si lver
.
,

beari ng tetrahe dri te pyrargyri te and nati ve silver; bis m uth silver mi nerals
, ,
-

are frequent ; s mall amou nts of gold are fou nd ; blende occurs i n consi der able

quanti ty The gangue i s quartz wi th kaoli ni te and rhodocrosi te ; b ari te i s

.

commo n; fluori te also o ccurs I n t he blanket deposi ts of Ri co oxi de s of i ro n

.

and manganese are promi nent N e ar the outcrop s the ores are ofte n complete ly
.

changed i nto sand carbo nate s I n 1 9 1 4 D olore s County furni shed about 2 50
.

tons le ad and Our ay County

,
i n the latter the Snefi els di stri ct i s the
leadi ng p roducer .

Lake County —Thi s i s sti ll one of the i mportant lead producers of the State
.
,

havi ng furni shed i n 1 9 1 4 over to ns of lead Of the deposi ts i n sedi mentary .

rocks those of Leadville are sti ll i n the lead The pri nci p al ore used to be .

arge nti ferou s gal e na wi th i ts se condary products of decomposi ti on — anglesi te ,

cerussi te and pyromorp hi te

,
The acce ssory m i neral s were blende and i ts
.

seco ndary p rodu cts carbo nate and sili cate of z i nc ,

The gangue consi sted of .

si li ca free and comb i ned i ro n and manganese and vari ou s clays charged wi th
, , ,

the same metals S uch ores are still mi ne d but form o nl y 6 p er ce nt of th e

.
,
.

produ ct of the di stri ct Of the oxi de or es there prevail sili cate and carbona te
.

of zi nc to an e xtent of 2 1 per cent Sulphi de ores e ncou ntered wi th i ncrease .

,

of dep th of mi ne form at present 58 per cent of the product ; of th ese 2 1 p er

,
.
,

ce nt are ble nde wi th pyr i te and some gale na and 3 7 p er ce nt pyr i te w

. i th l ead , .

and some copper .

Ch afi ee County This u sed to be an i mportant pro ducer of oxi de silver

.
-

lead ores occurr i ng i n li mesto ne The le ad produ ced i n 1 9 1 4 amou nted to 700
.

tons whi ch came mai nl y from mi nes worki ng sulphi de ore although some car ,

bonate i s sti ll produ ced Of the sulphi de ore some i s gal ena ; the bulk however
.
, , ,

i s a mi x ture of ble nde galena pyr i te and ch al copyri te ,

The Chalk Creek and
, ,
.

Monar ch di stri cts contai n the pri nci p al mi nes .

—
P i tki n County The le adi ng di stri ct i s that of Aspen whi ch came i nto
.

promi ne nce i n 1 884 The ores occur i n the same geologi cal hori zon as the
.

Leadville depo si ts but are not found at the co ntact of li mesto ne and erupti ve
,

rock ; they occur i n the hi ghly folded and faul te d li mestone as i mpregnati o ns
of fine gr ai ned argentiferous gal ena i n li mesto ne alo ng fault fissures The
-
.

di stri ct i n 1 9 1 4 produced tons of lead ; thi s came mai nly from sulphi de
—
conce ntr ate s as th e ore wh en mi ned co ntai ns 9 1 0 p er cent Pb and 3 oz Ag
,
. .

per ton present mai nl y as polybasi te Associ ated wi th lead are zi nc m i nerals . .

Table 1 6 gi ves anal yse s of some Colorado ores deli vered at present to smelteri es .
 LE AD ORE S 57

TAB LE 16 —. mu
O RE S urs n on COLORADO

Per cent .

0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0

M ontana — The argenti fe rous lea d ores of M ontana are i nsi gnficant i n
.

comp ari so n wi th tho se comi ng from the great copper deposi ts The produ cti on .

of lea d i n 1 9 1 4 w as near ly to ns ; of thi s 56 p er cent came from the mi nes ,

.

i n Sil v er B ow 1 0 per ce nt from C asca de and 9 per cent from Lew

, i s and Clark
.
,
.

Cou nti es The ore occurri ng as replacement vei ns i n gnei ss and igneous rocks
.
, ,

i s a mi x ture of silver be ari ng gale na and ble nde whi ch has to be concentr ated
-

,
.

Lea d co nce ntrate s of 1 9 1 4 shi pped to smelteri es averaged p e r ce nt Pb .

,

and lea d copper conce ntr ate s 2 3 2 6 p er cent Pb; the blende concentr ate av er
-
.

aged per cent Pb . .

N ewM exi co The lead producti on of t hi s State appears to be decr easi ng

.
-

havi ng fall en from tons i n 1 9 1 3 to 886 i n 1 9 1 4 The Magdalena Grant .

,

and Cooks di stri cts are the l eadi ng produ cers The deposi ts of Magdal ena .

Mountai ns o ccur i n P alaeozoi c li mestone whi ch has been cut by gr ani te por
h
p yy r di kes ; the o xi di z ed z o nes co n tai n l ead silve r and z i nc ; th e u n a l tered zone , ,

much ble nde wi th some gal e na and chalcopyr i te The deposi ts of the Grant .

and th e Cook s di stri cts form fissure vei ns i n porp hyry and grani te Table 1 7 .

gi ves analyses of some ore sh ipments .

TAB LE 1 7 —.O RE SH I P ME NTS FR O M NE W MEX I CO

Per cent .

0 1 2
58 ME TALLURGY or LEAD

0 The Paci fic Coast — rge nti ferous lead ores under th i s headi ng
The
5 . a

occur i n N evada U tah Idaho Ari zona and C ali forni a

, , , ,
.

N cod a — The producti o n of argenti ferous lead i n N evada has gr eatl y di m i n

i shod am,
o unti ng i n 1 9 1 6 to 1 1 to ns The ore used to come from the Ri ch .

mo nd and E ureka Consoli dated m i nes i n the E ureka di stri ct whi ch at prese nt ,

fur ni she s only about 1 00 to ns lea d The leadi ng m i nes are si tuated i n Li nco ln
.
,

C lark and Whi te P i ne Counti es wi th 54 38 and 8 per ce nt of the State s

, , , .
’

product ; the deposi ts form vei ns i n quartzi te li m s to ne and slate

e In Li ncoln , , .

Cou nty the P i och e di stri ct i s the most i mportant the ores are carbonate and ,

sulphi de ; i n C lark Cou nty the Y ell ow P i ne di stri ct fur ni shes zi nc lead su lphi des -

t o concentrati ng plants ; i n Whi te P i ne County the sm all amou nts of l ead ore

come mai nly from th e C herry Creek di stri ct w i th mi nes i n the nei gh borhood ,

of the smel ter town McGill The ore i s mai nly sulphi de o nly sli ghtly altered
.
,

to anglesi te and cerussi te Table 1 8 gi v es analyses of lead ore shi pments

. .

TAB LE 1 8 — 01
. mSmn p N rs n on NEVADA
Ounces per ton Per cent .

s
| s:o. Fe Mn
l CaO
I Spei ss

Utah — produ cti o n of thi s State i s of great i mportance havi ng

The lead ,

attai ned i n 1 9 1 4 the large figure of tons The argenti ferous lead deposi ts .

form more or less regular bodi es i n li mesto ne or at the contact of li m esto ne

and erupti ve rock The or es are carbonate wi th anglesi te stro ngly p revaili ng ;
.

the secondary mi nerals extend downward to co nsi derab le depths ; small amounts
of galena occur Many of the mi nes have been worked down to the sulphi de
.

z o ne
. T he leadi ng m i nes of the State are i n th e Bi ngham or West Mountai n
di str i ct The ores form an i rregul arly m
. i nerali z ed zone betwee n li mestone and
quartzi te and some ti me s porphyry The li mestone and porphyry are m
, . ore
or less decomposed near the deposi ts The lea d ore is carbonate co ntai ni ng .

more or less silver ferrugi nous clay and some gal ena The sili ceous ore i s
, ,
.

an oxi di zed sili ceou s pyri te Wi th i ncrease of depth the ores of the di stri ct
.
,

have ch anged to sulphi de and most of them must be co nce ntrated

, .

In the Ti nti c di stri ct occur as rep lacement deposi ts i n li mesto ne heavy

, ,

galena and carbo nate whi ch change in to sili ci ous ore runni ng hi gh i n lead and
c0p p er m ost of them go di rect to smelteri es .

The P ark C i ty regi on of Summ i t county has oxi de and sulphi de lead ores
as fissur es penetrati ng folded and f aulted li mesto ne quartz i te and sh ales ; , ,

the larger part of the produ cti o n comes from beds i n li mestone Most of the .

ores h ave to be e nri ched by concentrati o n .

 LE AD ORE S 59

Tooele C ounty Wi th the Ophi r and Rush Valley di stri cts i s promi nent
, -
,

pro ducers of oxi de and sulphi de lead ore i n the rati o of 3 1 .

I n B eaver Cou nty i s th e celebrated H orn Silver m i ne whi ch i s still a produ cer .

The ore su lp hi de wi th some carbo nate co m

, es mai nl y from rep lacement depo si ts
,

i n li mesto ne so me from co ntact deposi ts

,
.

Table 1 9 g i ves analy ses of ore rece i ved by sm e lteri es .

T AB LE 1 9 — ORE S . mu P E N rs rnou
'
UrAn

Di stri ct Per cent .

Li t tle Co ttonwood .

I daho .
—The a
rgenti ferou s lead ores are the most i mportant of the cou ntry ,

the S tate havi ng produced tons of lead i n 1 9 1 6 The mi nes worked at .

pres e nt li e i n four di stri cts the Coeur d Alene ( Shoshone County) the Texas
,
’
,

(L e mh i Cou n ty ) th e B i,rch Cre ek ( Fremo nt Cou n ty ) and the M i ne ral H i ll ,

( Blai ne County) The deposi ts of C oeur d Alene are fissure veins of varyi ng
’
.

T AB LE 20 .
— Co mmD A’
LE N E LE AD -
SI LVE R 02 3 5 1

Concentrates

Concentrati on
ra ti o

p er t on

Bunk er Hill and Sulli van .

Gold H unter

Hercules
Last Chance
Morni ng
Standard -
Mammoth .

1
Rowe, M i n . World , 1 909 , xxx , 4 2 8 .
60 M E TALL URG Y OF LE AD

thi ck ness i n Algonki an sedi mentary rock s such as quartzi te shale and sch i st , , , ,

whi ch have been mu ch folded The ore i s galena and galena blende i n the rati o .
-

of 3 1 and has to be concentrated The average assay of the lead ore s shows
,
.

9 per ce nt Pb an d 4.oz Ag per ton of th e lea d z i nc ore s per ce nt Pb a n d

.
,
-
.

6 oz Ag per ton ; the lead concentrates shi pped to sm

. el ters average per
ce nt Pb and
. oz Ag per ton . .

Table 2 0 gi ve s the tenor i n Pb and Ag of ores as mi ned the rate of co neen ,

trati on and the value s of Pb and Ag of th e co ncentrate s of some of the leadi ng

, ,

m i ne s .

Tab le 2 1 g i ves analy ses of some co ncentrates rece i ved by smelter i es in 1 9 1 6 .

TAB LE 21 .
— O RE SH IPME NTS n on COE UE D
’
ALE NE , I nAno

Per cent .

Ari zona and Cal iforni a — The produ ct of Ar i zona i n 1 9 1 6 was to ns . .

The lead i ng di stri ct i s the Warren or B i sbee ( Cochi se County ) The ores are .

mai nly sulphi de The average assay of the ore shi pped i n 1 9 1 4 was Pb
.

Cu per cent ; Ag Au oz per ton . . .

The produ ct of C ali fo rni a i n 1 9 1 6 w as a li ttle over 3 600 tons lead Mo st of .

the lead came from I nyo cou nty some from Shasta Cou nty ,
.

1 —
5 1 P u rch
.a s i ng L ea d S ilver O r es Th e tre atme nt of a lea d si lver ore i s -
.
-

both a metall u rgi cal and commerci al operati on ; hence the process u sed and th e
1
Ki rchofi , M i n Res U S 885, 2 81

m
. . . .
,
1 .

an, M i n Quart 1 893 94 x v 1

S chool .
— .

Austi n E ng M i n J 1 90 7 m m 2 2 6 ; Mi n S c Press 1 9 1 4
, , ,

, . . 1 70 , ,
. .
, , .

Barbour E ng M i n J , 1 9 1 1 x cn 364
, . . .
, , .

Gaetani Mi n S c Press 1 9 1 3 CW 684 7 2 4 ; M i n I nd 1 9 1 3 10 111 , 87 7

, . . .

m
, , , , . .
, ,

Turnbull, o p . ci t ,
1 9 1 6, cx ,
1 33 .

“
Ful ton, C R , Th e B uyi ng and Selli ng of Ores
. . and Metal urgi cal l
Products,
”
Techni cal
Paper 83 , Bureau of Mi nes, r9 1 5 ; .

Rep ort of S melt er and Ore Sales Investigati on Co mmi tt ee, State of Colorado, 1 91 7.
 LE AD ORE S 61

m anner of carryi ng i t out must be not only correct physi cally and chemi cally ,

but the resul t obtai ne d mu st make an adequate return i n re covery The pr i ce .

p a id a m i ne Op e ra tor fo r a l ea d o re w ill h ave to c over at l e as t th e v a lue of th e

net yi eld of metal the total co st of treatment and the pro fi t i t i s de si red
, ,

to make Thi s total co st of treatment i nclu des th e net co st the co st of trans

.
,

p o rt a t i on of met a l to th e re fi n er th e c o st of re
,
fin i ng th e se lli n g ex pe n se a nd th e , ,

transpo rtati on of refined metals to the consumer Th ere must also be made a .

dedu cti o n from th e market quotati on of the metal i n the pri ce pai d for the
metal i n order to furni sh a protecti on agai nst loss from the vari ati on of
market pri ces in th e large stock s that have to be carri ed i n the form of ore and ,

i nt ermed i ary or fini shed product .

In purchasi ng the character of lead bear i ng m i ne ral and the compo si ti on

,
-

of th e gangue h ave to be co nsi de re d as well as th e qu ant i ty of ore that i s ofl ered .

If th e lead m i neral i s a su lphi de th e ore gene rally will have to be roasted or

,

blastroasted ; if i t i s a carbo nate thi s i s not nece ssary , The gangue m ay be .

e i ther self fluxi ng aci d or basi c i e requi re no fluxes requ i re a base

-

, ,
. .
, ,

( F eO ,
M n O C aO ),
o r requ i re
,
an a ci d ( Slo g) to form a d e si r ab le sla g M o s t .

ores are sili ci ou s he nce basi c ore s are li kely to command a hi gher pri ce
,

than aci d I n purchasi ng basi c ore s the base pai d for i s F e wi th i ts

.
,

sub sti tute M n ; often CaO al so re ce i ve s some co nsi derati o n The so ca lled .
-

“
base e xcess i s that amou nt of avai lable Fe and Mn whi ch i s obtai ned by
”

addi ng the pe rce ntage of Fe to th at of Mn and dedu cti ng th e Si O 2 or Fe+ , ,

Mn Si 02 Base E xce ss
— = .

The i mpur i ti e s i n an ore afl ect i ts pri ce They m ay ne ce ssi ta te a p reli m

. i
nary roasti ng ( S As) ,
may h p ai r the fusi bili ty of th e slag (ZnO MgO
, , ,

or m ay cau se lo ss of Pb and Ag by slaggi ng or vo lati li zati o n (Zn As , ,

Sb) or finally m
,
ay re nder the lead i m pure (Zn As Sb Cu ) The p ri ce pai d , , ,
.

for an ore wi ll therefo re be i n i nverse rati o to the percentage of i mpuri ti es

present .

The quanti ty of ore ofl ered at a ti me will i nflue nce the p ri ce that can be pai d ,

as the large r t he amou nt the lower i s th e ge neral and th e spe ci al co st provi ded
, ,

of cou rse that the quanti ty ofi ered i s not exce ssi ve .

A smel te ry lo cated i n a rai lroad center draws i ts supp li es from a number of

mi ni ng di stri cts and can work more cheaply than one whi ch has been ere cted
i n a mi ni ng di stri ct furni shi ng only a si ngle class of ore Su ch a ce ntral plant .

trea ts not o nly argenti fero us lea d ore s but extracts the preci ous metal also from ,

real si l ver ore s called dry ore s on account of th e i r lack of le ad by m i x i ng th em

, ,

wi th ores that co ntai n mo re lead than i s requ i red for the charge Smelti ng can .

th us ofte n compete w i th m i lli ng on account of the hi ghe r pe rce ntage of preci ous
metal ext racted from th e ore .

I n b i ddi ng for an ore dedu cti ons are made for actual and po ssi ble lo ss
, ,

and for th e total co st of sme l ti ng whi ch will vary wi th th e cau se s me nti o ne d

, .

Th e value of lead i s gi ven i n per ce nt or what i s th e same i n uni ts of 2 0 lb .

, ,
.

to the t on of 2 000 lb The percentage i s determi ned by the dry or wet

.

assay . As th e latter gi ves figu res whi ch are from 1 per cent hi gher than .
62 ME TALLURGY OF LE A D

the fo rmer a dedu cti o n of thi s amount i s someti mes made f rom the wet assay
,

to arri ve at the dry assay whi ch i s the basi s of settlement In U tah a comb i na , .

ti o n method i s i n use whi ch determi nes i n the wet way the lead content of th e -

button Assays ought to agree wi th i n

.
p er ce nt T h e pr i ce s p a i d a re .

regulated not si mply by the fluctuati on of th e market but also largely by the ,

scarci ty or abu ndance of avai lab le lead ore at th e wo rk s N o payme nt i s made .

for lead if pre sent i n amounts of le ss than 5 per ce nt .

There are i n Operati on th ree methods for the payme nt of lead ore s 1
.

1 P aym ent by the uni t and quotati on a sy stem cu stomary i n Colo rado
. T he , .

“ ”
me thod i s based up on what i s called a quota ti on of p er 1 00 l b l e ad . .

“
The quota ti on i s not the sales pri ce i n NewYork but i s figured from t he
”
,

la tter I n mak i ng a settleme nt there i s added or deducted 1 ct per u ni t for

. .

eve ry ri se or fall of 5 cts i n the quotati on . .

If the sale s pri ce i n N ewYork i s th e q uotati on i s 90 per cent of thi s .

p ri ce or ,
If the sale s pri ce i n N ewYork li e s between and $4 50 .
,

the quotati o n i s obtai ned by adding to one half of th e exce ss of the sales -

pri ce over Suppo si ng th e sale s pri ce i n N ewYo rk to be per 1 00

lh the quotati on wi ll be
.
,
If the sale s pri ce
in N ew York i s hi gher than $4 50 the quota ti on i s obtai ned by addi ng to .
,

one half of th e excess of th e Sale s pri ce betwee n

-
and and all

of the excess above Suppo si ng the sales pri ce i n N ewYork to be

per 1 00 lh the quotati on will be .
,

$4 3 5 -

In Table 2 2 are gi ven mount

the a s pai d per u ni t of lead i n ore on the basi s
of a quotati o n .

TAB LE 22 .
— PAY E NT ron M LE AD 1N ORE ON B Asxs or Q U OTATIO N
Lead cont ent , dry assay,
Pri ce p er uni t
p er cent .
p er cent .

e t
In g the value of lead i n an ore contai ni ng 35 p er cent Pb w i th
asc r a i ni n .
,

the sales p ri ce i n N ewYo rk of $4 30 p er 1 00 1b we start w i th th e pri ce per u ni t . .

,

i n the table whi ch i s From th i s i tem have to be deducted as m

,
any ce nts

as the re are 5 ct u ni ts i n the di fl erence between -

and t he calcu la ted
.

quotati o n of Thi s difl erence i s 2 5 or five 5 ct u ni ts he nce a de du cti o n ,

-
.
,

of 5 cts per u ni t i s made from. the figu re of the table whi ch leave s ,

to be pai d per u ni t The amou nt to be pai d per u ni t of lead for the same ore .
,

wi th the sales pri ce i n N ewYork of p er 1 00 lb i s w i th the quota t i o n .

figure s above : $0 51 + 16 5 58 . .

1 Fulton, o p
. ci t .
, 23 .
64 ME TALLURG Y OF LE AD

whi ch the smelti ng charge i s to be fix ed as i t difl ers i n composi ti on from the ,

stand ard Thi s so called neutr al ore or neu tral schedul e vari es wi th the di str i cts
m
-
.

and di fl ers someti mes i n t he sa me locali ty T hu s —

an gave i t i n 1 893 94
1
.
-

for D enver Color ado as consisti ng of Slo g 30 Fe 30 Pb 1 3 Zn 8 S 5 per cent

, , , , , ,
.
,

credi ti ng for Fe C11 0 and to some extent for MgO + B aO and debi ti ng for
, ,

Slo g .Austi n gave i n 1 9 1 4 for Utah th e slag composi ti o n Slog 33 FeO 33

1 -

, ,

CaO 2 0 ZnO 8 p er ce nt as th e b asi s of calculat i on

,
A thi rd and more general
. .

stateme nt i s to de fine a neutr al ore as one i n whi ch th e Insolub le Resi due i s

equal to the sumof Fe and Mn i t co ntai ns and to make varyi ng rates for Fe , ,

CaO M gO B aO ZnO Algos S and As

, , ,
At prese nt some smel teri es have
, , ,
.

abando ned at le ast i n th e i r de ali ngs wi th m

,
i ne operators the i dea of a neutr al ,

ore ; they gi ve cre di ts for Fe Mn CaO debi ts for Insol ( Slog) S Zn As Sb Bi , , ,

.
, , , , , ,

and m ake supplementa ry charges for bri cki ng and treatment Foll owi ng .

the last co ncepti o n there are i n operati on at present the foll owi ng scal es of
pr i ce s .

I ran i s p ai d for at the rate of 5 1 0 cts p er uni t assays agreei ng to wi thi n

—
.
,

1 per ce nt .

Li m e i s p ai d for at the r ate of 2 5 cts per u ni t ; usually no p ayment i s made

— .

unless there i s prese nt a consi derable amou nt of CaO say 1 0 per cent and over ; , .

assay s are requi red to agree wi th i n 1 p er ce nt .

I nsoluble i s charged for at the rate of 1 0 1 2 cts per uni t ; assays agreei ng -
.

wi thi n 1 2 per cent

— .

Zi nc has no charge agai nst i t as long as the amount present doe s not exceed
5 p e r ce n t i n s ome cas e.s 1,0 per c e nt ; a n y ex ce ss i s ch a rged for at t he r ate of .

0— 0 t a u n i t a y mu t a ree w i t h i n per e n t
3 5 c s ; .ssa s s g 1 c .

—
S ulphur i s ch arged for at th e rate of 2 0 2 5 cts a uni t to a maxi mum of .

per ton of ore the assu m pti on bei ng th at this figure covers th e cost of
,

roasti ng an ore wi th 1 2 per cent S and over ; some ti me s th ere i s no pe nal ty for .

2 p er ce nt S . .

—
Arseni c Thi s i s usually figured as spei ss ; up to 5 per cent sp ei ss there is .

no charge ; any e xce ss over thi s figure i s charged at the rate of 2 0 cts a u ni t . .

Some smelte ri e s figure on As as such and charge 5 cts per u ni t i n exce s s of 1 .

p er c e n t .

Th e basi c charge for treatme nt i s per ten for an ore wi th 30 per cent .

Pb ; a credi t of 5 1 0 cts a uni t i s allowed for every uni t i n excess of 30 per cent
— . .
,

and debi t of 1 0 cts m ade for every u ni t below 30 p er ce nt

. Thi s tre atm e nt .

charge i s below co st but i s made up by not gi vi ng fu ll pri ce for lead , The .

r ati onal e of the se treatment charges i s gi ven by Austi n 1

,
.

T he fo llowi ng example will ill ustrate the manner i n whi ch or es are usu all y
pai d for at prese nt T he chemi cal analysi s shows : .

Insol 4 0 Fe 1 0 CaO 5 Pb 2 0 Cu 3 Zn 8 S 5 per cent Ag 50 and Au 1

.
, , , , , ,

oz p er ton
. The cr edi ts and debi ts w
. ill gi ve the net value per ton .

1
Loc . ci t .

1
Loc ci t.

m
.

1 Mi n Sc . . Press, 1 91 4, c ,
1 70 .
 LE AD ORE S 65

Per ton
Au, 1 oz .
p er oz .

Pb, 20 p er cent .
( wet assay ) mi nu s 1 .
5 uni ts p er

370 lb .
90 p er cent .
= 333 lb . cts .
)
Cu 3 p er cent
. i nus 1 . m uni t = 2 p er cent .
40 lh ; .

40 lb ( 1 7 5 cts )
.
-
.

Fe, 1 0 per cent 6 cts p er uni t . .

CaO , 5 p er cent 2 cts p er uni t . .

Total credi t

D ebi ts
T reat ment
Lead, 30 p er cent 8 cts p er uni t . .

I nsoluble, 40 p er cent @ 1 2 .

Sulp h ur, 5 2 ( free) = 3 p er cent @ 2 5 cts

-
.

Zi nc, 8 5 ( free) = 3 per cent

—
30 c ts .

Total debi t
N et to o wner , 5

52 . Purchasing Non the Mi ssi ssippi Valley lead -

argentiferous Ores .
— In

co nce ntr ates u se d not to be so ld and bo ugh t at le ast ofli ci ally by assay but , ,
“ ”
flat basi s “ ”
on a Th e repre sentati ve of the smel tery the buyer . we nt to , ,

th e di fferent mi nes and gui de d by previ ous exper i ence i n pur chasi ng from the , ,

sa me m i ne oflered a certai n amount p er ton

, Thi s has bee n changed In . .

so u th w estern Mi ssouri ores are sol d on a m arket b asi s after they have been

sa mple d and t he i r lead co nte nt s determi ned by wet assay The uni t q uanti ty
1 -
.

of lead co nce ntrate i s lb and not the usu al ton of lb Le ad ores are . .

p ai d for at the pri ce fixed i n St Loui s o nce a week usually Thursdays for ore
1 ‘

.
, ,

assayi ng 80 per cent Pb wet ; there i s made a de du ct i o n of a u ni t for .

every per cent of lead below the 80 per cent standard there i s pai d a premi um
.
-
.
,

of a u ni t for every per cent i n excess of i t Suppose a galena co ncentrate . .

co ntai ns accordi ng to the seller s assay per ce nt Pb and to the buyer s ’ ’

.
,

75 per c e nt T h e re s ul t
.s are aver aged gi v i n g per cent Let the basi c , .

p ri ce for 8 0 per c e nt be per lb T h e di fl ere nce . .

,

multi pli ed by $0 i s deducted from and fu rni she s the .

pri ce of to be pai d for lb .

I n southeast Mi ssouri lead ores are sold by yearly co ntracts on a metal

basi s and not on a market basi s as i n southwestern Mi ssouri I n Wi sconsi n Ii
.

1
Si nce the heavy increase i n N ew York quotati ons , t hi s charge has m
been te porarily
i ncreased to i n any i nstances m .

1
Clerc, E ng M i n J 1 885, XL, 4 . . .

Blak e, Tr A I M E 1 893, . . . .
564 .

Sp encer, Bull Mo M i ni ng Club, 1 , 1 886, No 2, p 51

m6 6
. . . . .

Fi nlay, E ng Mi n J 1 908 D o o 0

m
.
. . .
, , ,

1 Edi tor, E ng Mi n J 1 9 4 x cv1 9 00 .

mm N v mb
.
. .
, , ,
1
W ari ng W G Pri v ,
. .
, . co .
, o e er, 1 9 1 5 .

1 W i tti
ch E ng Mi n J
, . . .
, 1 9 1 5, c, 24 .

S
66 ME TALLURGY OF LE AD

the manner of selli ng lead ores i s si m ilar to that of southwestern Mi ssouri ,

Kansas and Oklahom a

m
.

53 M. etallu r gi cal Tre at en t i n Gener al — M etalli c l ea d i s ex tr acted from

i ts ores excl usi v ely by smel ti ng i n carbon heated fur naces E lectri c furnaces -
.

have been proposed e speci all y for zi nc le ad sulphi des but have not as yet come ,
-

i nto use Volatili zati on m

. etho ds h ave bee n suggested
1
.

If the ores are f ree from silver as e g i n the Mi ssi ssi ppi Valley the re , ,
. .
, ,

sulti ng lead usu ally goe s to market af ter i t has bee n i n p art pur i fied by

li quati ng and poli ng In a few i nstances such l ead i s desilveri z e d by the .

,

P arkes proce ss as the amount of i mpuri ty present i s co nsi derably reduce d

, ,

and the hi gh er p ri ce pai d for the better gr ade of lead and the small amou nt

of silver recovered make the oper ati on pro fitable I n 1 9 1 4 1 5 per cent of
1
. .

the lead from southeastern Mi ssou ri was desilver i zed If the ore i s argentifer .

ous the si l ve r passe s for the most p art i nto the le ad (le ad bulli on) whi ch i s
,

the n des ilver i z ed ( C hapter X ) .

Wet and electrolyti c me thods have found no general appli ca ti o n We t .

methods may be sui ted to complex zinc lead ores wh en mechani cal concen -

trati on has proved a fail ure i n sep arati ng blende from galena 1
The object of .

t he v ari ou s pro cesse s i s to render the zi nc soluble and furni sh a lea d re si due -

whi ch can be smelted sati sfactori ly as well as a zi nc so luti o n for the recove ry of
metal Processes of thi s character belong to the metallurgy of zinc rather
.

than to tha t of lead .

Of the num erous electrolyti c processes proposed only one that of Salom ‘
, , ,

has b een i n successful operati o n; i t produ ced spo ngy lead to be u sed i n storage
batteri es .

The smel ti ng of lead ores i s carri ed on i n three types of furnaces the rever ,

beratory th e ore hearth and the blast furnace

, Of these the first has become
-

, .

al mo st ob so lete ; the ore h earth i n re ce nt year s has become of co nsi derab le -

i mportance wi th a li mi ted class of ores ; the blast f urnace i s the lead i ng apparatus ,

as i t can treat q ui ck ly and e co nom i cally all k i nd s of ore s i n large quanti t i es .

1
Wells, M i n S c Press, 1 9 1 7 cxrv 507. .
, , .

Ralston Willi am s Udy Holt Ball A I M E

-
August - -

, . . . .
, , 1 91 7, p . 1 2 05 .

Larson, Mi n S c Press, 1 9 1 7, cxv 2 75 ( Bunker Hill )

. .
,
.

1
M i n Res U S Geol S urvey 1 9 1 4 , 1 1 00
. . . . .
, , .

1 M el Cher
. n E ng 1 9 1 6 X IV 3 1 . .
.
, , ,

Ri chards, Electrochern I nd , 1 9 —
3, 1 , 1 8 . . 02 0 .

m
Sale , Tr Arn Electrochern S oc , 1 90 2 , 1 , 87
. . . . .
 C H APTE R VII

54 . Introducti on — S u lph i de le ad ore s i n the reverbe ra tory fur

. n a ce melti ng s

was very common until wi thi n the last few years especi ally i n England Bel , ,

gi um and Austria wh ere sui table galena concentrates are avai lable Since the
1 1
,
.

adve nt of bla stroasti ng wi th sub sequent b last furnace sme l ti ng reverberatory ,

work has become nearly obsolete In the Uni ted States there were i n operati on
11
.

i n M i sso uri i n 1 877 fif ty si x reverberatory fu rnace s and i n 1 9 1 4 o nly four The -

, .

furnace i s do i ng very sati sfactory work i n the smelti ng of cyani de resi dues by
the Taver ner proce ss ‘
Thi s subje ct belongs however to the metallurgy of gold .
, ,

and si lve r and i s not treated here

,
.

The di scu ssi o n of reve rbe ratory work on ores has been retai ned wi th sli ght ,

modi fi cati o ns i n the pre sent edi ti on as the practi ce covers many metallurgi cal
, ,

consi de rati o ns of general i nte re st and of di re ct value to the r efiner of lead

bulli on i n the worki ng of hi s intermediary products .

O utli n e — T h pro e rr i ed n i n th reverber tory fur n i th

55 . e c ss ca o e
. a ac e s e

Roas ti ng and Reacti on or Ai f Reducti on Process whi ch as shown i n §4 1 i s based ,

°
upon the i nteracti on of PbS PbO and PhsO 4 at temperatures below 1 ooo C , , , .

whi ch sets free Pb and $ 02 Formerly the so called Preci pi tati on Process .
-

based upon the decompo si ti on of PbS by Fe was i n operati on wi th raw

“
o res at Vi enne and Poullaouen France and Chi cago ; also wi th ro asted ores
1
, , .

at Par and Po i nt Cor nwall Thi s p racti ce has been gi ven up on accou nt of the
7
.
,

hi gh cost and the large loss of metal .

The roast i ng and reacti on process i n the reverberatory furnace requi res two
ope rati o ns one followi ng closely upo n the oth er and both be i ng repeated
, ,

several ti me s .

1
Mi n . I nd .
, 1 90 1 , x, 4 24 .

1
Op . ci t ,
1 906 , xv, 533
1
Pulsi f er, Mi n World , 1 9 1 4 , XL, 1 1 4 8
. E ng . .

Taverner, J ChemMet S oc S Afri ca, 1 90 2

. . . . .
-
03 , In , 70, 1 03 , 1 2 1 , 1 34 ; Eng . Mi n J
. 1 903,

LXI , 75, 1 84 .

Cart er, op ci t , 1 50 . . .

Clevenger, Tr A I M E 1 904 xxx rv 89 1

. . . . .
, , , .

R usden, J . Chem M et M i n S oc S Afri ca. . . . .

,
1 90 5, v , 2 88 ; Eng . Mi n J . .
, 1 905, Lxxx , 688 .

Swi nney, Tr I nst Mi n M et 5 1 ; E ng

—
1 906 0 7, xvr, 1 Mi n J 90 7, Lxxxv111 , 608
'

. . . .
,
. . 1 .

M cGraw, op . ci t .
, 1 9 ,
1 2 v, 84 0 ; 1 9 1 4 , xcvn , 606
x cr .

Clark Sharwood, Tr I nst

-
Mi n Met , . .
—
1 9 1 2 1 3 , xx n , 1 3 2 .

m3
. .

Clark , Tr A I . . . M . E .
, 1 91 5, , .

1 Kerl, B .
, Grundri ss der Metallhti ttenkunde ,
Feli x, Lei p si c, 1 88 1 , p . 24 .

1
J ernegan, Tr A I . . . M . E .
, 1 8 73
—
74 , 11 , 2 79 .

1 “
Percy, Lead,
”
2 57 .
68 ME TALLURGY OF LE AD

1 .
—
Oxi dat i on The rushed fine enough to pass a 4 or 5 mesh si eve ore c -

, ,

—
i s spread i n a layer 3 4 i n deep over the hearth of the f urnace and i s heate d .

° °
gradually to a du ll red h eat ( 500 to 600 The roast i ng i s carri ed on i n such
-

a w ay that o nly a p art of the Pbs i s converted i nto Ph O and Ph SO . the res t ,

remai ni ng undecompo sed The temperature at whi ch thi s roasti ng i s carri ed .

on and the ti me gi ven to i t depe nd on the character of th e ore P ure galena .

requ i re s a lowtemperatu re to avo i d agglomerati o n; if py ri te bl e nde or calci te , ,

are pre se nt the roasti ng can be acce lerated ; the lower th e temperature the ,

more su lphate wi ll be formed Duri ng the operati on the fire on th e grate i s .

kept lowand open and the charge i s raked frequently to expo se as much of , ,

the ore as po ssi ble to the acti on of ai r and heat and to prevent agglomerati ng ,

whi ch ob structs oxi dati on .

2 Reducti on
. The se cond operati o n i s that of rai si ng the temperature to
.
-

about 800 C so that the o xygen compou nds m

°
.
,
ay react on u nch anged sulph i de .

The re sulti ng Pb runs down the i ncli ned hearth and colle cts i n a basi n the SO : ,

passes ofl th rough the flue and the resi due remai ns on the hear th The tem ,
.

p era t ure dur i ng th e redu cti o n per i o d m u s t be lo w so th at th e charge m ay be ,

only i n a pasty condi ti on as the reacti ons are very i mperfect if the ore i s melted , .

By well fi lli ng up the grate wi th fuel th e req ui red temperature i s obtai ned and
u nconsumed ai r excluded The charge i s stirred at i ntervals to bri ng sulphi de .

and oxi de co nst i tuent s i nto i nti m ate contact .

As i t i s not po ssi b le to roast a large amount of lead ore u ni formly i n one

operati on the first reacti on th at take s place on rai si ng the temperature wi ll not
,

extract all the lea d The resul ti ng p asty resi due wi ll be ri ch PbS co nsi sti ng
.
,

mai nly of PbS wi th some Pho PbSO 4 PbSiO 4 and gangue The temperature , , x ,
.

i s low ered and ai r i s admi tted A se cond roasti ng take s place and i s followed by .

a se co nd reacti o n I t take s seve ral repeti ti ons of the p roce ss to extract the
.

bulk of the lead Wi th ea ch one th e temperature mu st be sli gh tly rai sed becau se
.
,

the amount of le ad di mi ni she s To counteract the melti ng of the charge slak ed .

,

li me i s added whi ch acts me chani cally by renderi ng th e charge le ss fusi b le and

,

mo re spongy ; i t may also assi st th e proce ss chemi cally by li be rati ng the lead
and by de composi ng th e su lphi de thu s help i ng the si lver i n the resi due to pass ,

i nto th e lead Toward the end of th e proce ss th e re will not be e no ugh PbS left
.

to react on the excess of PhSO 4 and Pho To red uce these to Pbs and Pb and .
,

to make the charge more porous coal i s mi xed i n ; then the roasti ng and reacti on ,

can pro ceed ag ai n .

E ach su cce ssi ve operati o n w i ll be of shorter durati o n th an the p reced i ng one

and the lead each ti me a li ttle le ss ri ch i n silver The first lead m ay co nta i n .

four ti me s as much si lver as the last 1

.

5 6 P rodu .c ts —
T h e produ ct s of s me l ti
. ng i n th e reve rbe ra to ry furnace are
1 Lead ho ldi ng i n su spe nsi on parti cle s of ore and other soli d matte r whi ch
.
, ,

1
Falli ze, Rec Un . . Mi n .
,859 , v1 , 4 2 1 ; Berg H atten
1 mZ 1 860, xx 359 ; 863 , 11x 11 ,
1 2 85

mm
. . .
, , .

B ouhy, Ann . Mi n .
,
1 8 70 , x vn, 1 59 ; Berg H u tten .
'

mZ . .
,
1 8 70, , 3
8 2 ; 1 8 7 ,
1 mm ,

52 , 84 . 9 2 , 9 7, 1 5°
m
Tei ch ann, Z t B erg H utten S al . . . . Wes . i Pr ,
. . 1 866, x rv, 2 3 2 .
 S MELTI N G LE AD ORE S 69

are removed by li quati ng and poling If the ore contai ns arseni c anti mony .
, ,

or c0pp er som e of these elements comb i ne wi th the lead and have to be

,

removed by refini ng
2 Gray slag a m
. ore or less matted mi xture of lead lead sulphi de oxi de
, , , ,

sulphate sili ca te gangue ci nders and li me in varyi ng proporti o ns

, , , , I ts te nor .

in lead and silver depends on the character of th e ore and on the extent to whi ch
th e resi due has been trea ted i n the fur nace In some case s i t i s crush ed and .

wash ed to save only the metal li c lea d ; i n others e speci ally wi th silver beari ng ,
-

ores i t i s sme l ted i n the b last furnace

, .

3 F
. lu e d u st c ompo s-
ed of p art i c
, l e s of u n ch a n ged or o x i di z e d o r e of vo la t i li z ed , .

lea d that has been converted i nto oxi de carbonate and sulphate and of fuel , , , .

If the ore contai ns b lende oxi di z ed zi nc compounds wi ll also be fou nd , The .

‘

amou nt of flue dust fo rmed wi ll vary wi th th e temperature at whi ch the ro asti ng

-

and rea cti ng ope rati o ns h ave b een ca rri ed on and also wi th the ski ll of the ,

fumace m an i n mani pulati ng the fur nace and the charge

-
As i t co nsi sts pri n .

ci p all y of oxi di z ed compou nd s i t i s wo rked i n wi th sub seque nt charge s and ,

shorte ns the ti me requi red for roasti ng If very i mpu re e g through arse ni c .
,
. .
,

and anti mo ny i t i s sm elted i n the blast furnace wi th the gray slag The
, .

resu l ti ng lead i s hard and has to be refined .

4 H
. e a rth b o t t om c o n si st i ng of he a r th ,
m a ter i al so a ke d to some depth wi th
metal It i s worked up i n the same manner as the resi dues
. .

5 7 L i m.i t at i o n s — T h e ro as ti n g a n d rea ct i o n p r o ce ss i n th e reverbe r a to ry

furnace has the followi ng advantages : the ore i s treated i n the raw state ,

t he apparatu s i s i nexpensi ve i nferi or rawfuel i s u sed hardl y any fluxes are , ,

requi red th e bulk of the metal i n a pure sta te i s qui ckly extracte d at a lowtem
,

p era t u r e w i th li tt l e lo s s b y vo l a t il i z a t i o n an d if th e o re i s a rge nti fe rou s

,
th e

larger part of the si lve r follows the lead and only a sm all quanti ty i s left i n th e
,

resi due whi ch i s ei ther thrown away or treated at a hi gh er temperature in the

,

b last fur nace The grea t d i sadvantage of the method i s that i t i s very much
.

li m i ted by the character of the ore To be sui ted for the reverberatory furnace
.

an ore m ust be a ri ch gale na or a m i xtu re of gal ena wi th ca rbonate ( the fo rmer

prevai li ng ) that do es not contai n less than 58 per cent Pb 70 per cent bei ng
, .
,
.

a commo n figure It m ay not co ntai n more than 4 or 5 p er ce nt S i Og; and

. .

the non sili ci ou s associa ted m i nerals su ch as b lende pyri te chal copyri te
-

, , , ,

calcsp ar and bar i te m

,
ay be prese nt only i n sm all quanti ti e s
,
The pro ce ss .

requ i res much fuel and many hou rs of sk illed labor per ton of ore trea ted .

5 8 I n fl.u e n c e o f F o r ei g i M a t t e r — T h e qu a n t i ty a n d q u a
. li ty of le a d t h a t
ca n be obtai ned from a g i ve n lea d ore will depe nd largely on the natu re and

proporti on of the o ther co nsti tuents These may be si li ca and argi llaceous .

matter oxi des of i ro n li mestone ( dolomi te) bari te fluorsp ar pyri te chalco
, , , , , ,

pyri te blende antimo ny arse ni c silver ( gold) and oxi de lead ores
, , , , ,
.

S i l i ca and argi llaceous m atter have an i njuri ous i nfluence i n both stage s of

the process on account of the i r readi ness to comb i ne wi th lead oxi de I t has .

bee n fou nd by experi me nt that wi th more than 5 per cent of Slo g an ore cannot .

be treated by the roasti ng and reacti on pro cess But even su ch a small am ount .
70 M E TALLURC Y OF LE AD

as per cent make s i tself felt by coati ng parti cles of ore wi th the si li cate
.

that has been formed th us preventi ng the acti on of the ai r duri ng the first
,

peri od and ob structi ng the reacti ons whe n the temperature i s rai sed .

Oxid es of I ron — Si deri te i s someti mes found wi th galena ore s but most of i t
.
,

can be remove d by dre ssi ng th e ore befo re smel ti ng The sm all am ounts whi ch .

—
remai n wi th the galena q ui ckly lo se thei r C03 (380 4 1 5 C ) duri ng roasti ng ° °
.
,

and the Fe104 or P8 20; acts as a stiffe ni ng i ngredi ent whil e the lead i s be i ng

extracted .

Li m estone ( dolom i te ) act s on the whole advantageo u sly du ri ng th e e nt i re

proce ss as i t hi nders the fusi ng of the charge Any chemi cal acti o n i t may have
,
.

i s so sli gh t that i t can be regarded as practi cally i nert matter I t lo se s some of .

°
i ts CO: at about 800 C and i s to a small exte nt converted i nto CaSO 4 . The .

i nvesti gati o ns of H ofman and Mostow i tsch have shown that the redu cti o n of
1

° °
CaSO 4 by C to CaS begi ns at 700 C and i s comp lete at 1 000 and that CO be .

The re m
°
gi ns to act also at 700 C but fini shes the redu cti on at 850 9 00 — .
, ay be

formed th erefore some CaS duri ng the last and hottest stage of the p rocess .

Thi s CaS can act to some exte nt upon CaSO . formi ng C210 and SO, but even at
°
1 000 the reacti on i s i ncomplete becau se th e ne cessary i nti mate conta ct of
molecules i s not attai ned even i n a laboratory experi ment I t m ay also be .

oxi diz ed by the O of th e ai r whi ch becomes acti ve at 800 and ceases to be ,

°

efl ecti ve at about 9 when a mi x ture of approxi m ately 75 p er ce nt CaSO . .

and 2 5 per ce n t CaO i s formed Mo st of the lime stone will remai n unchanged
. .

and li ke all i nd ifferent sub stances will retard somewhat th e roasti ng by preve nt

i ng the ai r from havi ng free acce ss to the parti cle s of galena and ob stru ct i ng
the reacti o ns by i nterferi ng wi th the necessary inti mate contact of sulphi de and
oxide The hi ghest allowab le amount i s 1 2 per ce nt
. .

B ari te rem ai ns practi cally unch anged i n the reverberatory H owever .

,

B aSO , m ayundergo changes si mi lar to tho se of CaSO 4 and at lower tempe rature s .

Mostowi tsch has shown that the reducti on by C to BaS begi ns at 600 C
1 °
.

and i s comp lete at and that th e efl ect of CO starts at i s 98 per

cent comp lete at
. and 1 00 p er ce nt at .

°
Fluorspar whi ch m elts at 1 378 C
, also remai ns unchange d u nless i t ’
.

comb ines wi th b ari te and PbSO 4 and thus i ncrea se s th e f usi bi li ty of the charge .

Expe ri mental evi dence of the se p racti cal facts i s wanti ng .

Pyri te whi ch lose s 1 m

°
, ol of S at 700 C i s benefici al i n the fir st stage .I t favo rs . .

the form ati on of lead sulphate and assi sts the oxi dati on of galena through
80; li berated by the decompo si ti on of FeSO . or Fe, ( SO r) 3 Small quanti t i e s .

m
of pyri te have also a favorable eflect duri ng the reacti on peri od the Peao 4 ,

or o, maki ng the charge less fu si ble I f pre se nt to a co nsi de rable am ou nt .

,

say from 1 0 to 1 2 per cent too mu ch i ro n su lphi de remai ns i n the charge

1
.
,

1
Tr A I . . . M . E .
, 1 9 1 0, x u , 763 .

1
Metdllurgi e ,
1 909 , VI , 4 6 2 ; E ng . Mi n . J .
,
1 909 , Lxxxv m 60
, 1 .

1 Percy, “Lead ”
p 4 88 ,
. .

Bouhy, Ann M i n , 1 8 70, . . xvn, p . 1 79 .

72 ME TALLU130Y OF LE AD

furnace practi ce m
Th e reverbera to ry ay be classed under three mai n h eads

1. The Cari nthi an M ethod ; 2 T he E ngli sh M eth od ; 3 The Sil esi an M ethod . . .

60 The Cori nthi an M ethod

.
— T he characteri sti cs of thi s method are th e .

small ne s s of the charge ; the slow roasti ng so tha t for eve ry part of PbS one pa rt ,

of PhSO , and at least two of PbO are formed ; the lowtemperature at whi ch all
the op erati o ns are carri ed on ; and the ai mto ex tract all the lea d i n the rever
bera tory The h earth i s i ncli ned toward the flue and the lead i s co llected
.

outsi de of the fu rnace .

( )
a L ead sm elti ng a t Rai bl 1
C ari-
nthi a —Th e ore worke d i s gale na ( partl y , .

coarse wi th from 72 to 75 per cent Pb and partly fine wi th from 67 to 73

,
.
, ,

per cent Pb) ; i n excepti o nal cases the lead contents go as low as 58 p er
.

ce nt The othe r co nsti tuents of the ore are anglesi te ce russi te wulfeni te
.
, , ,

ble nde wi llem i te calci te fluori te and asbestos but th ese form only a very sm
, , ,
all , ,

quant i ty The foll owi ng analyses by Phi li ps i n 1 84 5 show the composi ti on

.
1

of lowgrade coarse and fine ore :

-

H O RIZO NTAL S ECT ION

I Vlenna loot d z
. “In ch es i n Engl i sh

FRONT ELEVAT IO N S ECT IO N O N LINE A B

-

F105 .
36 to 39
— Reverberator
.
y urnace, Rai bl, Ca ri nthi a. f

drawi ngs ( Fi gs 36 to 39) of the furnace showan i ncli ned hearth

The .

wi th o nly one worki ng door g belowthe flue d On the same si de i s the door , , , .
,

b le adi ng to the fireplace

, The grate sli gh tl y more i ncli ne d t han the hear th .
, ,

i s p arallel to the lo ng axi s of the furnace I t i s built of sto ne and has si x trans .

m B rg mZ Ofli ci al Rep ort , Oester Z t Berg H uttenw,

'

Th u , e . H utten . .
, 1 863, xx11 , 1 96; . . . .

D ow Blei vergi f tungen, H Older, Vi enna , 1 905, p t 1 , p 1 8 ; Mi n I nd ,

”
1 889 , n 9 7; , 2 Rep ort : . . . .

1 906, I V: 53 5
1
Ann Mi n . .
, 1 84 5, v mp ,
. 2 9 3.
 S MELTI NG LE AD ORE S 73

verse Op enings The firebri dge i s at c; the openi ng f carri es ofl any lead fumes
‘

.
, ,

i nto the m ai n flue The hearth term i nates at i ts lower end i n a cast i ron
.
-

gutter over whi ch the lead runs i nto the mol d Fi g 3 7 shows the support
,
. .

for the worki ng tools The fur nace i s buil t of sandsto ne and ordi nary red .

bri ck ; the worki ng bottom whi ch i s renewed every 4 or 5 weeks i s made , ,

by ta mpi ng down fir m l y fireclay probably a m i xture of rawand b urnt clay ,

.

I t i s made i mpervi ou s to le ad by glazi ng w i th gray slag Th e heati ng up of the .

-

furnace leadi ng to the fri tti ng of the slag i s done slowly to prevent the crack
, ,

i ng of the tampi ng Furnace s are usually built i n p airs bei ng placed si de

.
,

by si de They last from 5 to 6 years The fuel used i s cordwood later

. .
,

replaced by li gni te Di me nsi ons are gi ven on the drawi ngs and i n § 63
. .

The mode of Oper ati on i s as follows : the furnace b arely red hot from a ,
-

p revi ous charge i s repai red if necessary and the charge of about 4 00 lb i ntro
, , ,
.

duced through the worki ng door g and spread out over the upper part of the , ,

h earth near the bri dge to a thi ckness of from 1 54 to 1 16 i n N o fresh fire i s .

made the heat of the furnace and the glowi ng fuel from the previ ou s charge
,

f urni shi ng suffici ent h eat for the first slow roasti ng The ore contai ni ng a smal l .
,

amount of b lende i s raked every qu arter of an h o ur ,

Wi th pure g ale na the .

raki ng i s not repeated so frequently as the qui ck oxi dati on woul d li berate ,

sufi ci ent heat to make the ore cake The begi nni ng of th e cak i ng i s i ndi cated .

by i ts adh eri ng to the rake The roasti ng peri od has come to an end whe n .

th e blue sul ph ur fl ames di sappear drops of le ad are see n ne ar th e front end ,

of the h ear th and the ore feels sandy The roasti ng peri od lasts 3 hr dur
, . .
,

i ng whi ch ti me the charge i s r abbled from ei gh t to ni ne ti mes and from five

to si x sti cks of cor dwood are consumed The temper ature i s then raised and .

kept pretty uni form throughout the reacti on whi ch sets i n The attendant .

works hi s charge once every qu arter or half hour and rai ses the temperature ,

sl i gh tly wh e n th e flow of lead ceases Th i s se co nd peri o d lasts from 5 to .

6 hr consumes from 1 6 to 1 8 sti cks of woo d and fur ni shes the first h alf of
.
, ,

the lead whi ch on account of i ts freedom from i mp uri ti es i s called vi rgi n le ad

, , ,
.

The attendant nowstops firi ng u nti l he h as colle cte d the re si due from all p arts
of the hearth i nto one h eap H e the n takes a few shovelfuls of ashes and breeze .

from the ash p i t throws th em on the h eap of resi due and works them i n i n
-

, ,

order to remove lead and to re duce lead oxi de and sulphate H e then urges the .

fire as qui ckl y as h e can and the so called th ird per i o d of the process that of slag
,
-

redu cti on h as begun ,The fur th er m ani pulati ons are the worki ng of the resi
.

due and the sti rri ng i n of breeze of ch arco al until after 3 hr the rest of the
-

,
.

“
lea d the slag lead
”
h as bee n extr acted
-
Thi s h as to be li qu ated before i t .
, ,

can be m arketed .

The practi ce is var i ed i n some works by raki ng out the resi due after the
ash es and b ree ze h ave bee n sti rred i n and i ntroduci ng a newch arge Thi s i s .

worke d i n the usual way The resi due from thi s second charge i s not wi t h .

drawn but that from the first added and both worked together for slag le ad
,
-
.

In thi s case the redu cti on of the slag o ccup i es from 7 to 8 hr .

The final resi due is wi thdrawn from the furnace and sorted i nto gray slag
74 ME TALLURGY OF LEAD

wi th 4 per cent Pb whi ch i s thrown away and a product to be crushed and

.
, ,

co ncentr ated ; the he ads w hi ch assay from 50 to 60 p er cent Pb goi ng back to , .

,

th e f urnace i n one of the sub sequent resi due ch arges -

.

T here i s one fur nace m an worki ng 2 4 hr who has a helper dur i ng the -

,
.
,

day ( 1 2 later th e work w as do ne i n 1 2 hr shi fts -

. .

Tabulated re su lts are gi ve n i n § 63 Of the products no sati sfactory anal yses .

e xi st except of the lead .

TAB LE 23 .
— AN ALYS E S or CAR1 N mA 1 N LE AD

Vi rgi n lea d Slag lead

In fu rnace and method were at last gi ve n up

1 893 the T he Bel gi an .
3

rever ber atory fur nace i s nowi n use and i s worked by th e Silesi an method ( see

( )
b Lead S mlti ng Engi s, Belgi u
e at method of worki ng at E ngi s m .
L The
di fl ers i n some respects from that at Rai bl Th e ores are p ure They contai n . .
,

acc r o di ng to an aver age of sever al analyses : PbS ZnS PCS2

CaCO; 5 per cent and traces of silver They are free from arseni c
.
, .

and an ti mo ny .

The furnace has the ordi nary form of a reverberatory The hearth wi dest .
,

i n t he mi d dl e i s sli g htl y co ntracted at th e bri dge and narrows down consi derably
,

at th e flue The furnace has tw o doors one at the si de and one bene at h t he
.
,

flue below whi ch there i s a small kettl e wi th a sep ar ate fireplace to recei ve
,

the lead The fuel used i s bi tumi nous coal

. The furnace bottom oval i n .
,

cro ss secti o n i s 2 ft
-
8 % i n thi ck at th e top of the bri dge and i s i ncli ne d
, . .
,

toward the flue so that no lead i s collected i n th e furnace At the flue the ,
.

thi ck ness i s 1 ft i n The fur nace h as a brasque work i ng bottom. . .

The brasque co nsi sts of two p arts by volume of ordi nary bri ck clay and
one of coke grou nd fine e noug h to p ass a 4 me sh scree n Old bottoms con -
.
,

tai ni ng usually about 2 or 3 per ce nt Pb are ground up and mi xed wi th .

,

1
Oester J ahrb , . . 1 87 2, XX II , 8
3 9 .

1
Op . ci t .
, 1 8 79 , xxvn, 1 88 .

1
Oester Z t Berg H ittten ,
. . . m 1 89 3 , xu ,
2 83 .

1
Bouhy, Ann M i n , 1 8 70 , . . XVII , 1 59 ; rep ri nt , La fabri ca ti on du plomb D unod , , Paris,
1 870 ; also i n Berg H illtenrn Z . . .
,
1 870, xxx r
x .
3 8 1 ; 1 8 71 , XL, 5 2 E.
 S M ELTI NG LE AD ORE S 75

ne w brasque the brasque needed for one furnace bottom ( about 4 000
. All
lb of clay and 1 600 lb of coke ) i s p rep ared by two m
. en i n 2 4 hr I n addi
. .

ti o n to the ordi nary te st for the correct amou nt of moi sture ( that the brasque ,

when squeez ed i n the hand shall cohere i nto a l ump but not have sufli ci ent , ,

moi sture to adh ere to the hand) another one i s used that of throwi ng wi th force ,

a b all of brasque ag ai nst the wall to whi ch i t sh oul d adh ere ,

.

I n tampi ng a layer of brasque 8 i n thi ck i s first sprea d out evenly on the

,
.

bri ck hearth and ta mped down to 1 i n ; the seco nd 8 i n layer i s not rammed .
-
.

do w n so firmly bei ng re duced onl y to 2 % i n ; the subsequent layers are made

,
.

by usi ng smaller amou nts of brasque as when spre ad out they are o nl y about ,

4 or 5 i n t hi c k T h e bottom
. i s not i mpervi ou s to.l e ad wh i ch fi l ter s throug h ,

to a sli gh t extent collects on top of the u nderlyi ng red bri ck and also p asses
, ,

i nto th e joi nts A bottom lasts about 6 weeks I t wears ofl qui ckly dur i ng
. .

t h e first 2 weeks but the n resi sts pretty well abrasi on by the tools and co rro
,

si o n by che m i cal acti on .

In starti ng a furnace wi th a new bottom th e warmi ng lasts 6 hr sli gh t .

,

crack s th at m ay form are close d wi th brasque Then a sm all charge of .

2 2 0 lb of lowgr ade ore w

. i th from 4 5 to 4 8 per ce nt Pb i s sp read over the
-
.

h earth and the temperature rai sed gradually for 514 h r the ore bei ng raked .
,

from ei gh t to ten ti m es The brasque becomes superfici ally soaked wi th lead .

and coa te d w i th a mi xture of vari ous lead compounds more or le ss melted .

There resul t from thi s charge 4 lb of lead 5 lb of ri ch slag li ke m ateri al and .

, .
-

1 30 lb of matte li ke mate ri al contai ni ng 4 8 per cent

. Pb The charges are
-
. .

i ncreased i n wei ght and ri cher ore i s wo rked unti l after th e thi rd day the
,

furnace can do no rmal work .

Th e method of wo rki ng i s th e same as at Rai bl wi th the excep ti on that all ,

t he lead i s not e xtracted i n the reve rbe ratory The resi due form i ng 1 2 p er .
,

cent of th e ori gi nal charge and assayi ng from 1 7 to 2 0 per ce nt Pb i s smelte d

. .
,

wi th puddle ci nder i n a small blast furnace One fu rnace man wi th a helper

-
.
-

works a charge i n 1 2 hr Tabulated di me nsi ons and results are gi ven i n §63 . .

Th e subjoi ned analyses show the composi ti o n of the resi due :

T ABLE 24.
— AN ALYSI S or RE e UE

( )
c m
Lead S elti ng i n the Ai r Furnace .
1~—
Th e roasti ng and reacti o n pro cess ,

“
W illi am
1
s, Geologi cal Survey of Mi ssouri : I ndustri al Rep ort ,
’
1 8 77 , p p .
—
8 1 01 ; Tr .

A I M E , 1 8 76 77 3 1 4
. .
— . .
, .

Broadh ead,
“ Geologi cal Survey of Missouri , 1 874 , p 4 9 2 . .

I ngalls, W R , Lea d and Zi nc i n the Uni ted S tates, M cGrawHi ll Book Co , NewYork ,
“ . .
” -
.

1 908, pp . 63 , 1 1 2 and foll .

Pulsi fer, Mi n . E ng . World , 1 9 4 , XL,

1 820 1 1 48

The furnace has been used to a consi derable extent i n the Mi ssi ssi p p i Valley where i t ori gi
,
76 ME TALLURG Y OF LE AD

r d out i n the so called ai r fumaca i s gi ven here as the Ameri can i mprove
as car i e - -

ment of the Rai bl furnace .

The galena ore from the Mi ssi ssi ppi Val leyi s co ncentrated to a hi gh grade -

pure pro du ct rangi ng from 70 to 84 per cent Pb . .

The f urnace has a peculi ar constru cti on The drawi ng s ( Fi gs 40 and 4 1 ) . .

show an i ncli ned hearth c wi th e as chargi ng and worki ng doo r and f as di s

, , ,

chargi ng and cleani ng door ; be neath i s a small kettl e g i nto whi ch th e lea d , ,

flows as i t i s set free i n th e furnace The chi mney i s a sheet i ron pi pe Thi rteen
.
-
.

i nches from th e front the lower or po t end of the furnace — i s the firebri dge ,

b wi th fireplace a at ri gh t angles to the axi s of the furnace

, , ,
The bottom of t h e .

VERT ICAL S ECT ION O N LINE

HORIZO NTAL S ECT IO N O N LINE C D -

FI GS .
40 and 4 1 . f
— Ai r urnace
,
M i ssouri .

fu rnac e t i ron plate wi th 6 i n of gray slag or resi due mel ted upon i t
i s a cas -
. .

Cordwood i s used as fuel The cost of a furnace i ncl udi ng shed i s esti mated
.
, ,

by Broadhead at $550 .

The ch arge from 1 400 to 1 600 lb of gal ena of from p ea to hazelnut

,
.

si z e i s i ntroduce d th rough door e and spread evenly over the hear th

,
It i s .

ro asted for from I to 1 16 hr at a lowtemper at ure th e sh o rter ti m

. e bei ng suf ,

fici ent if the gal e na contai ns some oxi di z e ore D uri ng th e ro asti ng the .

charge i s co nstantly rake d and move d from firebri d e to flue and from th e cooler
g ,

part of the furnace to the hotter i n order to h eat and roast i t as uni fo rmly ,

as po ssi ble . When thi s i s accompli shed the heat i s rai sed and lead begi ns to
flow Ashes and breeze are used as stifl eni ng i ngredi ents The charge i s rab
. .

nated ; but i n 1 89 0 i t had gi ven w

even ay la rgely to th e ore hearth , as thi s has about th ree

m
ti es the cap aci ty, although i t reco vers a s aller a ount of lead m
The p ercentage of lead ore m .

worked i n 1 880 b difl rent f rn

u aces i n the Missi ssi i Valle as re ort ed b the T nth “
y e pp y, p y e ,
”
Census of the Uni ted States, vol xv, p 8 1 8, as as follo s : Ai r furnace,
. . w w Fli ntshi re
furnace, Scotch hearth , blast f urnace, p er cen t .
 S MELTI N G LE AD ORE S 77

bled at i ntervals When no more lead appear s (after from 7 to 8 hr ) the

. .

res i due i s drawn wi th out any attempt to extr act slag lead in the furnace as at -

Rai bl .

One furnace m an w i th a helper work s i n 1 2 hr a charge whi ch consumes

-
.

one and one half cords of wood -

Abo ut th e yi eld no thi ng i s known as th e .
,

lead content of ore charged i s not determi ned

-
Tabulated di me nsi o ns and .

resul ts are gi ven i n § 63 .

The followi ng two analyses by Wi lli ams sh ow th e compo si ti o n of resi due

1

and pole d lead from the Granby w o rks:

Resi due: Slo g Cao MgO Fegoa A130;
ZnO ent PhSO 4 per c .
,
PbS PbO total ,

p e r ce nt Th e samp le y
.i e lded p er c n e t of . mtal hc lead whi
e ,
ch make s the
total metall i c lead per cent .

Lead : As Cu Fe Sb Ag
Zn Ni Pb (by difl erence) total 1 00 p er cent ,
.

6 1 The Engli sh Method

.
— Th e ch aracteri sti cs of thi s method are a large
-

ch arge a qui ck roast (wi th the result that for every part of P hso 4 fo rm ed
,

FIG 4 2 . .
— Reverberato r
y urnace, S ti p ers to nes ,
E f
ngl a nd .

t h e re s all h
remai n two parts of PbS unchanged ) a hi gh temperature through ,

o ut ,
and th e ai m to ex tract all th e lead i n th e reverbe rato ry Th e hearth .

i n cli nes toward the mi ddl e of one of the si des ; the lead colle cts i n th e furnace ,

and i s tapped at i ntervals i nto an outsi de kettle .

( a) Lead S m elti ng at S ti perstones (S hropshi re)

1 — The ore i s a co ncentrate d
1
Tr . A I . . M . E .
,
— —
1 8 76 7 7, v, 3 2 0 3 2 4 .

1
Moissenet Ann Mi n ,
. .
, 1 86 2 , I , 4 5 ; rep ri nt, Trai te mnt e de la galene eu four gallois ,

D unod , Pari s, 1 86 2 ; also i n B erg H ittten . mZ . .

,
1 86 3, 2 4 3, 2 5 1 , 2 6 1 , 2 65.
78 ME TALLURG Y OF LE AD

galena wi th some carbonate and b lende assayi ng per cent Pb the

, .
,

gangue bei ng pri nci pally carbonate of li me .

The co nstructi on of the fur nace i s gi ven i n detail i n Fi gs 4 2 to 4 7 T he . .

horizo ntal secti on ( Fi g 4 2 ) shows the usual trapezoi dal fo rm of the E ngli sh
.

reverberatory w i th i ts three worki ng doors k on ei th er si de the well 6 at the

, , , , ,

front and the fire—ope ni ng t at the back I t i s to be noted that the centers of
, , , .

LO NG ITUDINAL S ECT IO N O N LINE X, Y, Z . V .

caoss S ECT IO N O N LIN E T , 0 .

FIGS .
43
— — Reverberator
4 4 .
y urnace, S t i perstonf
es, E ngland.

h e arth , a , and fireplace , g, are not opposi te each other , the latter , wi th fire
bri dge , 13, be i ng 1 0 i n further back The obje ct of thi s i s to draw away the
. .

’
flame from the well , b; for the same reason the flue , d , near the back , i s made
1 i n wi de r than flue d, near the fro nt , whi le both have the same h ei ght
. E ach .

has i ts own dam w w The ro ss secti on Fi g 44 , shows the i ncli na

’
p er and ,
. c -

, .

ti o n of the hear th from the back to the fro nt where well, b, i s placed .
 ME TALLURGY OF LE AD

a li ne 3 drawn from the taphole and the poi nts a and B are
ft . 6 i n lo ng i s .
, , ,

lo cated at a di stance of 1 ft on each si de of i ts i nner ex tremi ty To th em . .

,

li nes are then drawn from the comers 7 and 8 starti ng at an elevati on of , ,

2 ft 8 i n
. The si de walls are rai sed sli gh tly over the roof P and have a total
.
, ,

h ei ght of 5 ft 8 i n measured from the floor . The space between th e two i s

.
, .

’
filled wi th sand R ,

The i roni ng of the furnace i s clearly shown i n the figures The buckstays .

are 6 ft 6 i n long the ti e rod s bei ng sli pped ove r th em and ti gh tened wi th
. .
,
-

wedges The upper ti e rods reach over the furnaée; the lower ones j j are
.
-

,
'
,

turned down 1 ft at a di stance of 4 ft 6 i n The casti ngs are not shown wi th

. . .

sufli ci ent di sti nctne ss i n the drawi ngs .

S cal e for H g . “
S cal e for F ig . “ I
0
I
‘
1
1 2 8

FI GS 4 6 . and 47 .
— Wo rki ng and fire doors, reverberatory furnace , Sti perstones, E ngland .

The taphole plate ( Fi g 44 and y i n Fi g 4 5) is 5 ft long and 2 0 i n hi gh ;

,
. . . .

i t i s 2 in thi ck at the bottom increasi ng to 3 in whi ch i t reaches at a hei ght of 6

.
, .

i n and retai ns for the rest of the di stance

. Ei ght i nch es above the cente r of th e .

lower edge i s the taph ole mand 4 i n above thi s begi ns a narrow verti cal openi ng , , .

(4 by w i th a hi n ged doo r p o n l y 8 i n hi gh so tha t w h e n the door i s cl o sed

m
9 , , .
,

a small cu rre nt of cold ai r ay pass ove r the mol ten le ad i n th e well Th e .

taphole plate i s overlapped on each si de by five cas t i ron plates (4 ft lo ng and 36 -

.

i n thi ck ) placed h ori zo ntally (z and z i n Fi g 4 They extend from th e

'
.
.
,

worki ng openi ng down to the taphole .

The b ack plate ( 5 ft long 2 0 i n hi gh and 1 i n thi ck) i s placed j ust opposi te
-
.
, .
.
, .

the taphole plate I ts mai n obje ct i s toprotect the b ri ck from the gray slag
.

wh i ch i s d rawn out from the back door To faci li ta te thi s two hooks H .
, ,

( g
F i . ca r ry i n g a n i ro n rod ( 3 ft 6 i n lon g a n d I i n i n di amete r ) as . . .

support for th e wo rk i ng too ls are placed i nsi de of ne i gh bor i ng buckstays -

,
.

The b ri dge plate n ( Fi g counteracti ng the long i tudi nal thrust of the
-

, .

hearth gi ves strength to the 4 i n ai r space o and p revents any leakage of

,
-
.
-

, ,

lead I t i s 6 ft long and 2 0 i n h i gh

. From the upper edge wh i ch i s on a
. . .
,

level wi th the grate bars i t i s 3 i n thi ck for a di stance of 6 i n then sud ,

. .
,

denly increase s to double that thi ckness for another 6 i n and for the last -

.
,

8 i n returns to i ts ori gi nal th i ckness

. .
 S MELTI NG LE AD ORE S 81

Th e worki ng ope ni ng s k have a number of castings door frames , , . The -

( B,
Fi g i n c l o si ng .e ach an ope n i ng 1 0 by 6 ln are 4 i n squ a re i n cro ss .
,
.

secti on T hey are protected on the si des by firebri ck and on the bottom by
.
,

the h ear th On the level of the grate bars or 2 ft 8 i n above the floor are
.
-

,
. .
,

two hori zontal plates C 6 in wi de and M in thi ck that extend below the , ,
. .
,

si x wo rki ng openi ngs On them re st two i nclined ( 3 : 8) plates E 8 i n wi de .

, , .

and i n thi ck whi ch abut agai nst the bottom of the door fram es
.
,
Tw o -
.

pla tes F of the same si ze as C form the upper part Of the li ni ngs The skew
, , , .

backs G (9 i n wi de and 54 i n thi ck) resti ng on th ese upper p lates F and the
, . .
, , ,

door frames B support the roof Th e si des of the worki ng openi ngs are li ned
-

, ,
.

wi th ln j am b plates as shown i n Fi g 4 2 Th e cast i ron wo rki ng doo rs q

-
.
-

,
. .
-

, ,

wi th handle r ( Fi g are placed agai nst the doo r frame s B

, .
-

, .

The cast i ron kettle c i n front of th e taph ole i s 2 ft 6 i n i n di ameter and

-

, , . .

2 0 i n deep . I t i s i mbed ded i n clay whi ch i s i nclose d on three si de s by maso nry

.
,

and on the fo urth by the slag bottom I ts ri m 8 i n above the floor i s sur -
.
,
.
,

ro un ded by an i ron hoop 4 i n wi de and M i n thi ck Wedges T are dri ven ,

. . .
, ,

between i t and the kettle to p revent any lead that may penetrate through the
joi nts and collect under the kettle from rai si ng i t ,
.

Th e fire O peni ng t 1 0 by 1 2 i n h as an i ro n casi ng ( Fi g

-
I t i s closed by , , . .

a sw i ngi ng fire door ( Fi g consi sti ng of firebri ck h eld toge the r by a wrought
-
.

i ro n frame The grate consi sts of two sets of cast i ron grate b ars of e i gh t each
.
- -

supp o rted at the end s by cast i ro n cro sspi e ce s -

.

Th e h oppe r (x Fi gs 4 3 and 4 5) i s a truncated sheet i ron pyrami d 36 and ,

.
-

6 i n square at the end s and 3 ft h i gh

. I t i s suspended i n a wooden frame . .
,

K ( 3 i n square) whi ch rests on two i ron cross beam s L 4 by 6 i n The se are

.
,
-

, , .

suppo rted by b ri ckwo rk 1 4 i n hi gh for m i ng th e conti nuati on of the si dewalls , .

,

of th e fu rnace Four i ron rods N ( Fi g fastened i n the wooden frame K

.
, .
, ,

have at thei r lower ends a sh eet i ron frame 0 on whi ch i s p laced a movable -

, ,

sli de whi ch closes the di sch arge of the hopper

,
The 6 i a ope ni ng i n the roof .
-
.

of th e fu rnace over whi ch th e mouth of the hopper i s placed i s i ndi cated on the
, ,

hearth i n Fi g 4 2 I t i s 1 ft 9 i n di stant from th e firebri dge and 2 ft 6 i n from

. . . .
, . .

th e worki ng openi ng nearest th e b ri dge at the b ack of th e f urnace .

W h en the furnace i s fini sh ed th e wo rki ng bottom made of coarsely broken , ,

gray slag and sand i s put i n P art of th e materi al i s spread out on the bri ck , .

bottom whi ch has previ ously been made red hot It i s h eated till i t becomes
,
-
.

pasty and i s th en patted wi th paddle and rake A second p art i s made to

,
.

adh e re to th e fi rst and so on u nti l the enti re bottom has been bu il t up wi th ,

successi ve laye rs of gray slag and sand and has attai ned th e desi red fo rm and ,

thi ck ness The upper edge of the well i s 1 0 i n below the wo rki ng openi ng
. . .

The th i ckness of the worki ng bottom i ncrease s toward the taphole It i s 4 i n . .

at th e b ack doors 1 2 at the bri dge 1 4 at the flues 30 at the front and 8 at the , , , ,

back of th e well .

The furnace bei ng bui l t soli dly lasts a lo ng ti me ; the roof of the fireplace
, ,

requi res repai ri ng every 2 years that of th e he arth every 5 years The , .

hearth i s rep ai red after every ch arge if ne cessary .

a
82 ME TALLURGY ’
OF LE AD

T hi s furnace has the representati ve form of the E ngli sh reverberato ry .

Sli gh t vari ati ons e xi st as regard s detai l For i nstance the foundati on i nstead .
, ,

of bei ng bui lt up soli d at the b ack someti mes has an arch ed vaul t at j ( Fi g
1
,
.

e xtendi ng lo ngi tudi nally comm uni cate s wi th the ai r space in the firebri dge ,
-

and i s accessi ble at the flue end of the f urnace Another vari ati on i s bui ld .

i ng the e nti re hearth on cast i ron plates re sti ng on rai ls supported by a

1 -

bri ck pi llar Someti mes the general form of th e hearth di flers by havi ng a
'

ge ntle slope toward the taphole Thi s makes the si des of the well less steep .

than tho se of the drawi ngs .

The tools used i n the furnace are sh own i n Fi gs 48 to 6 1 They are o f . .

wrought i ron wi th the excepti on of the mold ( Fi g 60) and the handles of shovel
-

,
.

( g 5 )
F i .2 an d ash p i t hoe ( g
Fi -
.

Fi gs 4 8 to 51 : Paddle rak e old paddle u sed as chi sel and hammer to

.
, , ,

remove adheri ng slag are the tools for worki ng on the hearth Fi gs 52 to 55 : . .

Coal shovel hammer to break coal fire poker and ash p i t hoe are requi red for
-

, ,
-

,
-

firi ng Fi gs 56 to 61 : Tappi ng bar re ctangular ski mme r ci rcular ski mme r

. .
-

, , ,

ladle mold and lead carri er are use d i n handl i ng the l ead
, ,
-
.

FI GS .
4 8 to 6 1 .
— Tools reverberator
, y urnace, f Sti perstones, England .

Method of doors may be desi g

Worki ng To si mpli fy the descri pti on the
—

m a ted by numbers 1 2 , 3 i n fro nt and 4 5 6 at th e b ack starti ng both ti mes

, , , , ,

from the bri dge .

The ch arge 2 350 lh i s droppe d from the hopper through the roof i nto t he
, .
,

furnace sti ll red hot from a previ ous ch arge the dampers havi ng been clo sed
,
-

,
.

The lead i s left i n the we ll and covere d wi th li me The ore i s spre ad w i th rakes .

over the hearth th rough doors I 4 and 5 I t decrepi ta tes and gi ves ofl
’

.
, ,

vapor of water Then the dampers are sli gh tly rai se d and the fire i s gradually
.

i ncreased for 1 M hr D uri ng the first 2 hr (first firi ng) the ore i s turned over
. .

four ti mes wi th paddles through doo rs 1 and 4 the other doors bei ng k ept ,

clo se d Th e paddli ng requi re s only a few m i nutes

. When the first firi ng .

i s nearly accompli shed fee di ng of fuel i s stopped and doors I 2 4 and 5 , , , , , ,

fire door and dam

-
pers are thro wn Open and the charge cooled ( first coo li ng) ,
.

1 “
Percy, Lead, p p
” —
222 22
.
9 .

1
Phi lli ps Bauer an, -
m p
o . c it ,. 1 89 1 , p, 64 0 .
 S MELTI NO LE A D ORE S 83

Thi s lasts for 16 hr Th e g rate i s the n freed

. from cli n ker s an d the ch a rge , ,

nearly 6 i n deep ne xt to the bri dge whi ch has fri tted i s broke n up and
.
, ,

turned over Any ore that had fallen i nto the well i s raked up on the furnace
.

bed Th e doors are nowclosed the dampers lowered the grate i s well filled
.
,

wi th coal and the se cond firi ng begi ns Thi s lasts from 55 to 60 m

,

, i n and . .
,

i s followed by a seco nd cooli ng Some lead nowflows i nto the well N ear the
. .

bri dge and toward the center of the furnace parts of the charge have begun to ,

fuse whereas at the flue the ore i s only si nte red The charge i s worked as i n
, .

th e first cooli ng door 6 nowbei ng also u sed ,

After 1 0 m i n the le ad whi ch has . .

accum ulated i s tapped from th e well i nto the kettle The taphole i s closed .

from the i nsi de by i nserti ng a clay plug fixed to a wooden handl e through the
li ttl e taphole doo r and pressi ng i t i n unti l the clay oo zes out i n fro nt Before .

tappi ng fine coal and wood shavi ngs are put i nto the kettle to pole the lead
,
-
.

I t i s th en sti rred vi gorously for 6 or 7 m in w i th th e re ctangular ski mmer .

to bri ng all the i mpu ri ti es to the surface These are removed fir st wi th .

,

th e sh ovel and then w i th the rectangular ski mmer and thrown b ack i nto the ,

furnace through doors I and 3 on bo th si des of the well The charge nowfreed
, ,
.
,

from part of i ts lead i s turned over wi th p addles through doors 1 and 4 Thi s
, .

ends th e seco nd cooli ng 4 hr after chargi ng The doo rs are now closed , . .
,

coal i s put on th e gr ate and the dampers are lowered to beg in the th i rd fi ri ng
,
.

M eanwhile the lead i n th e outsi de kettle is ski mmed and ladled i nto molds
holdi ng 1 2 0 lb Thi s takes about 2 0 m . i n D uri ng th e thi rd firi ng whi ch .
,

las ts 2 hr the ore i s tu rned over several ti mes care bei ng taken to ope n
.
, ,

the doors as li t tl e as po ssi ble The furnace shows a full yellow hea t when the.
-

thi rd cooli ng begi ns Th e charge i s nowwo rked wi th paddles for 1 5 or 2 0 m

. in .
,

and parts of i t th at have colle cted i n the well are sti fl ened by the ad di ti o n of

li me and are raked on the hea rth Th e r esi due on the hearth i s collected near .

the b ri dge and fine coal wo rked i nto i t The doors are agai n closed the fire i s .
,

urged for a quarter of an hour and the resi due turned over wi th the paddle ,

thro ugh doo rs I and 4 and final ly drawn out th rough door 5 Any repai ring
, .

of the h ear th that may be necessary takes place now and the furnace i s ready ,

agai n for a newcharge 7 hr from the ti me whe n the previ ous one w , . as first

i nt rodu ced .

Tw o m enwork as p art ners i n 1 2 h r shi fts Tabu lated result s are gi ven -
. .

i n § 63 .

( )
b S melti ng N ear H o lyw ell N or th W ale s — T h i s difi e r s from
'
t h at a
,t S ti p er .

sto ne s Accor di ng to Percy i t i s as follows

1
.

After droppi ng the charge of 2 350 lb on the he arth and spreadi ng i t Over .

the upper p art of the bed the doors of the furnace and th at of the fire box are
,
-

left O pe n for 1 14 hr to let the ai r have free acce ss dur i ng the first roasti ng
.

stage w h i le the damper i s rai sed just e nough for the g ase s to e scape
,
Work .

i ng doors 3 and 6 and the fire door are now closed and the fire i s urged -
.

Lea d soo n app ears D uri ng t hi s h e ati ng whi ch lasts 2 hr doors 2 and 5
.
,
.
,

are closed but I and 4 are kept ope n

,
Through the se the charge i s rabbled at .

1 “Lead ”
, p . 232 .
84 ME TALLURG Y OF LE AD

i ntervals . Toward
of thi s first reacti o n peri od lead begins to flow the end .

N owdoors 1 and 4 are closed th e damper i s thrown Open the fire urged for 4 0 , ,

mi n and the charge melted down The fur nace is then cooled for half an
.
,
.

hour by throwi ng ope n all the do ors What cha rge remai ns on the h earth i s .

rabble d doors 3 and 6 are closed Slaked li me i s thrown through door 2 on the
, ,

charge whi ch has collected i n the well and worked i nto i t through the tap hole
, ,
“
door The sti fi ened resi due i s colle cte d ( set up ) near the bri dge as well as
.
”
,

other parts that have bee n detached from the hearth D oors 2 and 5 and the .

fire do or are now closed th e damper i s lowered and the temperature raised
-

, ,

gradually for half an hour whe reupo n the damper i s enti rely thrown open , ,

doo rs I and 4 are close d and the fire i s urged to melt down the resi due whi ch , ,

takes 2 0 mi nutes T he fire door and the worki ng doors I 2 4 and 5 are th en
.
-

, , ,

t hrown open li me i s added through door 2 and worked i nto the slag to thi ck en
, ,

it
. The lea d i s tappe d and the sti fl gray S lag r aked out on the floor through ,

door 5 The lead i s pole d as at Sti p erstones and the hear th repai re d if
.
, ,

necessary The e nti re ti me req uired to work the charge is 6 hr

. .

Tw o fur nace m en and one h elper work two ch arges i n a 1 2 hr

-
shi ft -
. .

Tabulated re sul ts are gi ven i n § 63 .

T he changes t hat take p lace i n the ore duri ng the process have been ex
am
-

i ned by Percy and are gi ven h ere i n th ei r lead co nte nts only
1
, .

T AB LE 25 .
— AN A LY S ES or CH AN GE S or GALE N A IN RO ABT I N G AN D or GRAY SLAo

Hours after chargi ng

Total Pb 66 22

( ) c S melti ng at De log
M o T hi s p lan t has one E ngli sh and t hree s e, Flat Ri ver, .
—

Silesi an reverberatory furnace s for ores and one blas t fur nace for reverberatory ,

slags whi ch are too r i ch to be di scar ded In 1 9 1 4 o nly two rever beratori es
1
.

were i n operati on and the gr ay slag was sold to other s melteri es ,

.

The Si lesi an fur nace whi ch w as at first co nstru cted on the model of th e ,

one Sh own i n Fi g s 6 2 6 7 w
— as not succe ssful prob ab ly on accou nt of the lack .
, ,

of the ski lled labor requi red I t was therefore rebui lt wi th the sump i n the .

mi ddle of one si de followi ng the example of the E ngli sh reverberatory ; but the ,

rectangular Silesi an form was retai ned .

1
Op . ci t .
, p . 2 35 .

1
I ngalls, E ng . Mi n . J .
, 1 905, Lxxx , 1 1 1 1 .

Pulsi fer, Min . E ng . World , 1 9 1 4 , X L, 1 1 52 .

1
Mi n . Res U S . . .
,
1 91 4, 1 , 1 02 .
 S MELTI NO LE AD ORE S 85

The hearths of the two remodeled furnaces are 1 6 ft long and 1 1 ft w i de that . .
,

o f the thi rd fur nace i s 1 6 by 1 3 ft The wi dth of 1 3 ft i s too great for sati s . .

fact ory work ; i t is held that a wi dth ought not to exceed 1 0 ft Of the four work .

i ng doors on a S i de the pai r near the flue i s kept cl osed on accou nt of i nsufli ci ent
,

tem perature i n that p art of the furnace t e the furnace i s too long for the ,
. .
,

E ngli s h met h od of work i ng .

Th e hearth 1 6 by 1 1 ft i s fired from a grate 8 by 3 ft ; the rati o of hearth to . .

g ra t e area i s th er efore 1 The gr ate li e

s 6 i n b elow the fir e doo r ; the b ars . .
-

are 36 i n lo ng I i n t hi ck at top 4 i n deep at m

.
,
i d dle and 2 i n deep at ends ;
.
,
.
,
.

the Open sp aces i nclu di ng ri b i n m i d dle are 3 2 i n long and

,
in w i de T here ,
. . .

are t w o flues 1 6 by 1 8 i n each wi th a damper,

The sheet steel guyed chi mney .
,
.
-

6 ft from the f urnace i s 4 2 ft hi gh and 4 2 i n in di ameter and has a bri ck ped

.
, . .
,

e s tal 64 by 64 i n and 1 3 ft hi gh ma ki ng the total he i gh t 55 ft

,
. The worki ng .
, .

doo rs 36 i n above the floor have cast i ron frames 7 by 1 1 i n on the i nsi de
,
.
,
-

, .

and 1 5 by 2 8 i n on the outsi de and are hel d i n place by buck stays

. The , .

sum p holds a cast i ron kettle of 1fi i n metal whi ch i s set partly belot he floor
- -
.
,

li n e so that t he di stance to the wo rki ng door i s 3 1 i n and to the tappi ng door 7 .

i h ; th e la tt er forms an openi ng 4 by 9 i n i n the

. i n cast i ro n plate The .
-
.
-
.

tap h ole 3 5 i n i n di ameter i s on a li ne wi th the ri mof the kettle The fur

,
. .
, .

nace costs $ 2 000 excl udi ng the chi m ney The wo rki ng h eart h 8 i n thi ck i s .
,
.
,

of b roken gray Slag beaten down firmly on a layer of bri ck whi ch rests on a fill
i ng of r ammed clay Fi ri ng a furnace after repai rs for from 8 to 1 2 hr
.
, , .

b ri ngs i t to the proper temperature ; Illi noi s coal se rve s as fuel The method of .

wo rki ng i s that of the E ngli sh reverberatory The ore i s a galena concentrate .

wi th abo ut 70 per cent Pb A furnace i s manned by a smelter and a helper who . .

get th ei r ore flux and fuel and whee l away the gray slag and ashes Wi th
, , ,
.

three 8 hr shi ft s each wo rki ng a charge of 3500 lb wet ( 332 5 lb dry) concen
-
.
,
. .

trate the sch edule of ope rati ons i s the one gi ven i n Table 2 6
,
.

TAB LE 2 6 — SC HE DU LE or . RE VE RB E RATO RY OP E RATIO N S AT D E S LO O E

D rop ch arge Begi n tap p i ng

Rak e out slag .

Begi n tapp i ng
D rop ch arge

Begi n Begi n firi ng down .

Begi n tapp i ng .

Rak e out slag .

Begi n tap p i ng .

Atbegi nni ng of the reacti o n peri od that i s 5 hr after droppi ng the

th e , .

charge from 8 5 to 1 00 lb cru sh ed fluo rsp ar i s th rown i nto th e furnace and

,
.

worked i nto th e charge the doors are clo sed and the fire i s u rged The first , , .

tap yi e lds about 1 2 00 lb lead Chi p s of wood and bark are placed on the . .

lead wh i ch i s po led and then ladl e d i nto pi gs wei ghi ng about 80 lh ; the
,
.

l Fi ri ng Do wn at t h e begi nni ng of the react i on p eri od means raki ng out th e enti re bed of coal and then
bui ldi ng a fresh fi re wi t h cord wood and mp coal
lu .
86 ME TALLURG Y OF LE AD

dro ss k i mmi ngs are retu rned to the furnace At the end of the S hi ft t he
and s .
,

gray Slag i s raked out i nto a barrow and wheeled outsi de the bui ldi ng It i s .

sold w i th a p ayme nt of 9 5 p er ce nt of the Pb content i f i t assays o ver 40 p er .

-

cent Pb and 90 p er cent if under

.
,
The co al consumpti o n i s to n p er . .

ton of ore Treatment of 1 0 1 2 to ns wet

. to ns dry) concentrate wi th
70 per ce nt Pb o r to ns lead g ave
. to ns or p e r ce nt i
p g lea d ; , .

to ns or 2 7 per cent gray slag assayi ng 38 per cent Pb whi ch i s equal to .

,
.
,

to ns lead Assumi ng 90 p er cent extracti o n by smelti ng i n the blas t

. .

furnace gi ves to ns lead The total ext racti on i s the refore

,
.

tons lead or per cent Tabulated results are

, .

gi ven i n 563 .

The co st of smelti ng i n 1 905 wi th five furnaces each t rea ti ng three ,

ch arges i n 2 4 hr i s gi ven i n Table 2 7 . .

TAB LE 27 .
— CO S T or REVE RB E RATO RY SME LTI N G Ar D esLocE

Labor and materi al s

1 f oreman at
5 crew s at

21 t ons coal , unloadi ng at 6 ct s

14 t ons lead, loadi ng at 1 5 ct s .

Coal, 21

Flux and sup p li es

G rand total .
$1 2 1 9 1

On the basi s of
to ns wet conce ntrate p er charge thi s co st would be ,

t n Th e a c tu al co st for 7 mo nt hs i n 1 900 w as p er to n : Labo r

p er o .
,

co al flux and supp hes ,

mi scellaneous tot al , , ,

Fi guri ng the co st of smel ti ng gray slag at p e r ton a nd t h e p ro du ct i o n of ,

gray slag at 5 per t on of wet co nce nt rate t h e total co st per ton wet charge ,

i s abo u t or per ton dry charge ,

Smel ti ng i n the reve rbe rato ry fu rnace w as replace d i n 1 90 5 by blast roasti ng

i n H unti ngton H ebe rlei n pots and sme lti ng i n the blast furnace
-
.

Bi rnbaum draw s a val u able compari so n betwee n the wo rki ng of th e t w

1
o

p ro cesses at Tarno wi tz Si lesi a ,

.

62 Th e Silesi an M eth od
.
— The characteri sti cs of thi s method are a large .

char e slow roasti ng and a low temperature I t i s no t ai me d to ex tract all

g , ,
.

the ead i n the reverbe rato ry as thi s i s supp leme nte d by the b last furnace
'

.
,

The hearth i s i ncli ned tow ard the flue bene ath wh i ch the le ad i s collected and ,

tappe d at i ntervals i nto an outsi de kettle .

1
Z t B erg B atten S al
. . . . Wes . i Pr ,
. . 1 90 5, L111 , 2 1 9 ; E ng . Mi n J. .
, 1 905, LXXX , 53 5, 680 ;
Mi n . I nd .
, 1 90 5, XIV, 0
4 5.
88 ME TALLURG Y OF LEAD

.
w
fro nt part ( Fi g 64 ) slo s down to the level of the ri mof the kettle th e lowest ,

part of the well .

The latest i mprovements of the Tarnowi tz furnace Sho w n i n Fi gs 66 and , .

6 7 have been devi sed to make the work less dangerous and u nheal thy
, Th e .

gray slag when drawn from the furnace i s not nowdi scharged on to the floor
, ,

or i nto a water box expo si ng the laborers to heat and fume or to exp lo si ons but
-

, ,

i nto a S lag pot d placed i n a ni che a whe re the slag m

-

, , ay coo l a nd the fumes

, ,

pass back i nto the furnace through the Ope ni ng Further the fumes i ssui ng .
,

HORIZO NTAL S ECTION O N LINE 0, H .

LONGITUDI A
N L secrlou ON LINE A B
'

.
,

FI GS . 62 and 63 —. f
Reverberat ory urnace, Tarno i tz , Si lesia w .

from the basi n after th e lead has bee n tappe d i nto i t do not pass i nto the b uildi ng ,

but are drawn ofl by a telescope stack h The ni che a 30 i n wi de 2 614 i n , .

, ,
.
, .

deep and 2 614 i n hi gh forms an Ope ni ng beneath the drawi ng door b ( to

,
.
, , ,

recei ve th e slag pot d whi ch is b rought on a sep arable car) the back and si des
-

, , ,

of whi ch are i nclose d by bri ckwork the roof bei ng formed by a heavy cast i ro n
,
-

plate whi ch supports the bri ckwork and the hearth The plate has an ope ni ng .
,

c 7 16 i n squ are ( beg i nni ng 1 5 i n f rom the outsi de wall) through whi ch th e
, . .
,

gray slag i s raked i nto the pot I t is clo se d wi th an i ro n plate when not i n
.

use When the Slag i s bei ng draw n the front of the ni che i s closed bya movable
.
,
 S MELTI NO LEA D ORE S 89

sh ee t h on door havi ng a peephole ; all the fumes from the slag pass through the
-

draw i ng O pe ni ng c b ack i nto the furnace

, ,
W hen i t has cooled sufli ci ently .
,

the slag pot i s covere d wi th a p i ece of Sheet i 1 0n and run out on the car
-
The .

telescop e stack h whi ch i s balanced by counterwei ghts i s lowere d to the posi

, , ,

ti on k as Soon as the lead i s to be tapped when the fumes will pass 03 through
, , ,

VERTICAL S ECT IO N O N LINE E. F .

VERTICAL S ECTION ON LINE C.

CROS S S ECT IO N T H RO UG H DOO R N EAR FIRE BRIDG E

FI GS . 64 , 65 and 66.
— Reverberatory furnace, Tarnowi tz , Si lesi a .

the sta t i o nary heet i ron pi pe g The be nefici al efi ect of these i mprovements
s -

,
.

is shown by the fact that w hi le i n the year 1 88 7 88

—
p er ce nt of th e men ,
.

beca me lea de d i n 1 89 1 9 2 o nly

, per ce nt were thus afi ected
-

. .

T he too ls requi red to w ork a furnace are four paddles four large and two ,

sm all r abb le
s five S hovels ( two for li me two for co al and one for slag) three
, , , ,

steel bars ( two large o ne s and a small one) a tapp i ng bar a ski mmer a ladle ,
-

, , ,
90 M E TALLURG Y OF LEAD

a sa mp le -
ladle , two sli ce bars -

,
a sl edge two hammers
, , and four hooks for hand
li ng the lead .

M ethod of fur nace if new i s brought to a dark red hea t ;

Worki ng — The , ,

the damper i s then closed and the charge crushed to pass a 5 mesh si eve ,
-

droppe d from the hopper t hrough the openi ng i n the roof and sprea d out
evenly over the hearth by means of rabbles to a thi ck ness of from 3 to 4 i n .

The fire i s fed wi th ci nders and the temperature never allowe d to exceed dark
,
° °
re dness say 500 or 600 C The gale na decrepi tates the temperature ri ses
,
.
, ,

CROS S S ECTIO N O N LIN E E -

F

Fro . 67 — Reverberatory urnace, Tarno i tz , Silesi a

. f w .

the ore becomes a dark red and after from three quarters of an hour to an
-

,
-

hour the ro asti ng begi ns D ur i ng thi s ti me the charge i s turned over o nce
.

wi th the paddle The wo rki ng doors and fire doors are ope ne d and th e
.
-

damper rai sed sufli ci ently to allow SO , and other gases to p ass off Th e .

ore roasts on the surface When the fumes begi n to lessen samples are take n
.
,

to see i f a whi te crust of oxi de and sulp hate has been formed Thi s i ndi cates .

t hat i t i s ti me to renew the surface whi ch i s generally do ne by paddli ng or ,

rabb li ng every 2 0 or 2 5 mi n i e about ei ght or ni ne ti mes dur ing the 3 or 4 h r

.
,
. .
, .

requi red for roasti ng C are i s taken to prevent the ore from clotti ng
. .

Up to 1 885 the roasti ng usually took about 3 or 3 16 h r but the gradu al .

i ncrease of blende i n the ore brough t the req ui red ti m e up to 4 hr In 1 886 .

i t became ne cessary to m ake a change i n wo rki ng the ch arge Thi s could .

be do ne i n two ways E i ther the no rmal ti me could be prolo nged or part of

.

th e ore ro asted separately The latter metho d w as cho sen and now
. one qu arte r ,
-

of the charge fine co ncent rate s especi ally ri ch in blende i s roasted separately
, ,
 ME TALLURGY OF LE AD

If the hearth sho uld become so i ncru sted as to rai se the charge too hi gh to
be protected by the firebri dge from the di rect acti o n of the flame the tempe ra ,

tu re mu st be rai sed so as to soften th e accumulated re si due that i t m ay be

remove d A hearth lasts abou t 3 months

. .

Th e result s from 1 year s ( 1 865) work i n a small er furnace 1 1 ft 9 i n by

’
. .
,

1 0 ft 1 0 i n
. wi th Si x doors and w
. i th ore lowi n blende and w i thout the di fferent
,

addi ti o ns were : ,
lb of ore ( assayi ng per cent Pb and . oz Ag) . .

gave 6384 lb lead bulli on ( assayi ng

. oz Ag) ; 1 59 2 lb resi due p e r . .

cent Pb and oz Ag) ; 2 75 lb flue dust p er ce nt Pb an d oz Ag) ;

-
. . . . .

showi ng th at i n th e reverbe rato ry per cent of the lead and .

per cent of the si lver was recove red i n the form of lea d bulli on Of the
. .

p er ce nt of lea d formi ng
. the difi eren ce per ,
ce nt w as re cove red i n ,
.

th e blast fu rnace so t hat the actual total loss a mou nte d only to
,
per cent .

The consum p ti on of fuel was lb or 4 6 per cent of the ore charged .

,
.
,

and of li me 1 00 lh or 1 p er cent Tabulated results are gi ven i n 563

.
,
. .

Th e followi ng anal y si s of resi due w as made by Pi etsch i n 1 865 : PbO

PhSO . PbSi O a Zuo FeO FeS CaO

C A130; and MnO t e
rac s, Ag =
( 4 .
36O oz .
p er ton)
total per cent .

The flue dust i n —

1 88 1 8 formi ng per ce nt of the ore charged had
-

, 2, .
,

accordi ng to D obe rs and D zi egi eck i th e compo si ti on gi ve n i n Table 2 9 .

TAB LE 29 — CO
. MPO S ITI O N FLU E DU ST -
AT T ARN o wrrz

Totals 1 00 28

. m
63 Co pari son of Reverberatory M ethods — To facili tate compari so n,
the mai n data of the furnaces di scu ssed have been brought together i n Table 30 .

In ompari ng the amounts of ore treate d i n 1 2 hr at the di fferent smel ti ng

c .

wo rks the order i n whi ch they are placed i n the tab le shows a steady i ncrease
,

from Rai bl to Tarnowi tz The figure for Tarnowi tz 82 50 lh requi res the .
,
.
,

explana ti on that the ch arge contai ns a consi derable proporti on of oxi de ore ,

whi ch Shortens th e ti me requi red for roasti ng If the ore were pure galena .
,

twi ce the ti me or 8 hr should be allowed Thi s would make the amount

,
.
, .

for 1 2 hr 61 87 lb The large amount of ore treated i s due to the si ze of the

. .

furnace As to the amount of labor re qui red p er ton of ore the table shows
.
,

that Tarnowi t z uses less and Rai bl more than anv of th e other smelti ng works .

Wi th fuel the same i s the case As the wear and tear of a furnace depend on .
 S MELTI NO LE AD ORE S

woman; A 3 11 04 1 1 1111135

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ME TALLURG Y OF LE AD

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-

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 CHAP TE R VIII

S MELTIN G LEAD ORE S IN TH E ORE H EARTH -

64 Introducti on of treati ng hi gh grade galena ore Thi s anci ent method

1~ - -
. .

has undergone many vi ci ssi tu des At first the only meth od for wo rki ng low .

Si li ca galena ores i t w as largely repla ced by the reve rberato ry furnace and thi s
, , ,

as has bee n Shown has see n i ts best days Si nce the i ntroducti on of the bag
, .

hou se to collect fume the ore hearth has taken a newlease of life so that i n 1 9 1 4 ,
-

i n Mi ssouri there were in operati on 75 ore hearths wi th an annual capaci ty

1 -

of tons galena concentrate The bag house h owever i s costly as .

, ,

regards i nstallati on and operati on The excellent results that have been ob .

tai ned wi th the Cottrell ele ctri c process for th e collect i on of fine du st and es

p e c i ally of f ume po i nt to th e prob ab ili ty of i ts replaci ng fil trati o n as the co st ,

both of i nstallati on and operati on i s low .

Wi th the i nventi on of the N ewnam mechani cal furnace the leadi ng

di sadvantage s of hard manual labor and of exposure to lead fumes have bee n so
di mi ni shed that i n the near future a larger output i n lead than i s the case at
present may be expected .

The process carri ed on in the ore hearth i s mai nl y the roasti ng and reacti on -

process It resembles that i n the reverberatory furnace wi th t hi s di fl erence

.
, ,

th at oxi dati on and reducti on go on Si mul taneously and tha t carbon i n addi ti on ,

to sulph ur acts as a reduci ng agent the charge floati ng on a bath of lead The , .

Pho and PbSO 4 as soon as fo rme d react on unde compo sed PbS ; some Pho
, ,

i s reduced by C ; and th e li berated Pb tri ckles through th e ch arge i nto the

hearth bottom overflowi ng i nto an outsi de kettle
,
.

The same condi ti o ns are as nece ssary for th e hearth trea tment as for the
x c i n h a h —
reverberatory wi th the e ept o t t t e Pb content usually 70 per cent
, , .

Should not be less th an 65 per cent and th e ore shoul d be coarser The sm allest
1
. .

permi ssi ble si ze i s that of a p ea and nut Si ze i s desi rable If fine ore i s to be ,
-
.

treated i t must first be pugged or agglome rated i n a reverberatory furnace

,
1
,

as i n th e ore hearth i t would be blown away

-
A hea rth requi re s power and a .

blower and mu ch lead i s volatili zed ; hence i t i s not sui ted for argenti ferou s ores
, .

Thi s rul e whi le true i n a general w

,
ay has to be qualified by the fact that sil ver ,

1 Pulsi fer, Mi n . E ng . World ,

1 9 1 4 , X L, 50 1 .

1
Pulsi fer, Mi n . E ng . World , 1 9 1 4 , X L, 1 1 53 .

1 D wigh t , E ng . Mi n J , . 6 , cu, 6 7 7,
. 1 9 1 1 0 2 6.

Garli chs, op . ci t .
, 4
9 ,8 1 0 2 6 .

Choate, op ci t ,
. . 1 02 7 .

1
Mi ddleton, E ng . Min J . 1 90 5, Lxxx , 1 0.

96
 S MELTI N G LE A D ORE S I N TH E ORE H E ARTH -
97

beari ng ores need not be excluded The late W W Petraeus about 1 895 di d . . .
1

treat su ch ores and found that whi le some si lver was fo und in the du st very , ,

li ttl e w as detected i n th e fume

1
Wi th the recovery of dust i n flues and of fume .

i n bag houses both of whi ch are trea ted i n th e blast furnace the loss i n m
,
et al ,

by du sti ng and volati li zati on i s re du ced .

The comparati ve loss i n Pb at Rai bl in where ore h earth and ,

-

reverbe ratory worked on the same ore wi th i mperfect means of conden ,

sati o n ,
was to p er ce n t Th e ore he a r th requ i re s pu rer a n d .
-

hi gh er grade ore th an t he reverberatory furnace but consumes less fuel ,

.

Accordi ng to Tunner ‘
a furnace si mi lar to the one at Rai bl consumed , ,

p er 1 00 lb of gal e na c
. u ft of wood w hi le the ore h e arth requ
,
i re d . .
,
-

onl y cu ft Th e ore hearth has three ti mes the capaci ty of th e ai r

. .
-

furnace The cost of treatment per ton of ore i s th e same wi th a si ngle

.

ore h ea rth ; wi th seve ral runni ng si de by si de i t be comes less as o nl y one set of

-

men i s necessary to run the more powerful engi ne and thi s consumes relati vely ,

l ess steam than the smalle r one That th e ore h earth cannot compete wi th th e .

E ngli sh or Silesi an reve rberatory furnace s as regar ds capaci ty and cost i s clea r .

I t has however one advantage over all reve rberato ri es that i t i s qui ckly starte d
, , ,

and stoppe d wi thout much consumpti o n of fuel ( u sually about 5 per cent of .

th e wei gh t of the ore) or loss i n heat and th u s se rves i t s pu rpose i n ex tracti ng ,

at i nte rvals from sm all amo unts of non argent i fe rous ore the major part of the -

lead . Thi s i s p rob ably the reason w hy i t found such favo r i n the Mi ssi ssi ppi
Valley where small amounts of ore were often treated and sti ll are by m
,
en w ho , ,

ha ve mi ne d i t th em selves .

Th e p racti ce i n the di fierent ore hearths i s so very mu ch the same that -

no thi ng from a general poi nt of vi ew need be sai d about i t .

Th e product s are si mi lar to those of the reve rbe ratory ; the re i s h owever an , ,

i ntermedi ary p roduct a mix ture of ore slag and fuel call e d browse i n E ngland, , , , ,

whi ch goes back to the charge i n the ore hearth The gray Slag produced -
.

contai ns mu ch lea d and i s smelte d ei t he r i n an ordi nary blast fu rnace for le ad

, ,

matte and slag or i n a small blast furnace known as the slag eye furnace if
, , ,
-

whi te p ai nt i s to be produ ced Th e fume whi ch i n forme r ti mes use d to be .

,

recovered i mperfectly i s nowcoll ected i n a bag house si ntered and smelted , , ,

ei th er w i th gray Slag and other lead beari ng m ateri als i n an ordi nary blast -

furnace or wi th gray slag alone i n a Slag eye furnace for whi te pai nt and
‘
,
-

waste Slag .

65 Influence of Forei gn Matter I t has already been sai d that the ore
.
— .

subje cte d to h e arth treatme nt mu st be pu re r and ri cher than i s ne cessary for

the reverbe ratory furnace Thi s i s be cause the forei gn matter shows i ts bad .

1
Pri vate mmuni cati on co .

1
Thi s p lan of trea tment has been p atented by O H Pi cher, U S Patent No 9 2 0 388, .
-

m
. . . .

May 4 , 909 ; E ng Mi n J , 1 909 , nor

1 , 2 56 . . . .

1
Oester Z t B erg H i lttenw, 1 888 XXXVI , 3 2 0
. . . . . .

1
Leoben J ahrb , 1 85 2 , I , 2 6 2
. . .

1
Pott eens, C . V , U S Patent N o
. . . .
588 2 8 9 ,
Aug . 1 7, 1 89 7 .

7
98 ME TALLURO Y OF LE AD

i nfluence i n a more marked degree The chemi cal acti on i s however the sam e .
, ,

as th at descri be d i n 558 .

66 Furnaces An ore hear th bei ng a lowfireplace surrounded by three

.
— -

walls wi th one or more tuyeres at the back cannot Show much vari ety i n con ,

stru ct i o n or i n m anner of ope rati ng H owever seven di fl erent forms have been .
,

chose n by w ay of illu strati on The Scot ch the Ro ssi e the E agle Pi cher the .
, ,
-

Ori gi nal Water back the Moffet the Modern Water back and the New
-

, nam ,
-

, .

FRO NT ELEVATIO N

HO RIZONTAL S ECTIO N
ON LINE. A B -

VERTICAL S ECTION ON LINE , C D -

1 0 l 2 8 4 5 0 7 8 9 10
M A —_I— l_ _J — _ L— _ J

FI G S . 68 to 70 — Scotch . ore -
heart h, Newcastle , E ngland .

1 . The S cotch Ore hearth represent the furnace used by

-
.
1 -
Fi gs .
1
68 to 70

Messrs Cookson .Co near Newcastle i n the N orth of England . The cast , .

i ro n hearth box or well a whi ch holds th e lead i s set i n b ri ck wo rk q I t i s

-

, , ,
-

, .

2 ft from front to b ack and about 2 ft 6 i n w

. i de ; i t i s 1 ft deep and h olds about . . .

2 tons of lead In some furnace s the depth i s only 6 i n and the capaci ty of
. .

1
Percy, Lead, p . 2 78.

Sexton, E ng M i n J , 1 89 5, LIX , 1 75
. . . .

Mi ddleton, op ci t , 1 905, LXXX , 1 0

. . .

1 “Ei hth Annual Re ort of the Local

g p G o vern, ment Board
—
8 78 79 , sup p le
”
1 mnt contai n
e

i ng the Rep ort of t he Medi cal Ofi cer for 1 8 78 London 1 8 79 , p 2 8 1

. . . .
1 00 ME TALLURGY OF LE AD

thi ck there i s left

,
p e by an ai r s ac
i n The blast ente rs at E passes
-
.
,

th rough D lea ves at F and i s deli vered to the tuye re openi ng G 2 i n above th e
, , , , .

top of A By thi s arrangement the Si des and back of the h earth walls are ai r -

coo led and th e b last i s heated

,
.

The characteri sti c of the mode of operati ng w as that th e hearth coul d be

worked conti nuously ; hence i ts smelti ng power was greater than that of th e
Scotch h earth but th e hot blast caused greater loss of lead by vola ti li z a ti on
, .

For thi s reason th e h earth w as abando ned Data are assemble d i n Table 3 2 . .

In our days all the fume s are recove re d ; the h eati ng of the blast by thi s si mpl e
means i s not out of place as i s seen by i ts rei ntroducti on at Granby and Webb
Ci ty Mo and Galena Kans The furnace was i n ope rati on i n 1 906 a t
,
.
, , .

several Austri an smel te ri es Th us Gai li tz had si x furnaces bui l t aro und a

1
.
,

ce ntral chi m ney Sch eri an has two S i m il ar ly p laced and Kreuth two
, We t , .

co ndensa ti o n of fumes i s co mmo n at th ese p lant s .

FI G S .
73 and 74
— E agle Pi ch
. er Lead Co -
mp any o e hearth
r -
.

3 Th e E ag
.le Pi cker Lea d Co Ore hearth T hi s
-
modern form of ai r cooled .
-
.
- -

ore hearth i s shown i n Fi g s 73 74 Th e h earth , 5

- —
ft 5 i n long and 1 ft 8 i n
. . . . . .

wi de has ai r cooled si de s and back ; the blast i s th ereby heated for the tuy e res
,
-
.

The lead pot i s placed on one si de the slag box p rovi ded wi th a sp ri nkler on
-

,
-

the o ther Fu rnace s are set back to back wi th an i nte rveni ng Space 3 ft w
. i de . .

The hood s whi ch carry off dust vapor and gas end i n a mai n flue whi ch i s , ,

provi ded wi th hoppe rs placed between pai rs of furnaces From them dust i s .

drawn off i nto carts The fume i s collected i n a bag house whi ch contai ns for
.

every furnace 2 80 bags 1 8 i n i n di amete r and 3 2 ft long The blue powder . . .

colle cte d by th e b ags i s bu rnt i n the u su al way and smelt e d w i th gray Slag i n a
slag eye furnace for sub li me d le ad pai nt
-
The blast p re ssure i n the furnace i s .

7 o z per .squ are i nch a nd over .

1
Government Report on Blei vergi ftungen, etc .
, H Older, Vi enna , 1 905 ; abstract , Mi n
.

I nd
.
, 1 906, xv, 533 .
 S MELTI NG LE AD ORE S I N TH E ORE H E AR TH
’
-

In hr the ore hearth treats

24 . lb lead ore assayi ng 75 per cent Pb ; -

. .

requi res 1 2 000 lb coal and 4 000 lb li me ; and pro duces 1 2 00 lb metalli c lead
,
. . .
,

lb gray slag 2 2 40 lb flue dust and 504 0 lb fume

. Data of the ore , .
-

, . .

hearth are assembled i n Table 3 2 .

4 The O
. r i gi nal Am eri can W ater back Ore hearth L— Fi gs 75 a nd 75a
1
S h ow - -
. .

the larger si z e d furnace wi th three tuy ere holes mat the b ack where th e older -

, , , ,

small er fo rm had only one The hearth box e ( fill ed wi th lead th e charge of .
-

, ,

ore and charcoal floati ng on top ) i s set i n b ri ckwork n It hold s about , .

2 500 lb of lead . The work sto ne g leadi ng to th e kettle h forms a separate

.
-

, , , ,

casti ng from th e hearth box The three si des of the furnace are fo rmed by a -
.

FI GS .
75 and 750
— Ori gi nal A . meri can wate r -
back ore hearth .

wa ter -
t o j acket cc 16
cool ed cas a tuy e re p late re sti ng
-
ir n , ,
1 in . thi ck , call ed -

on t he hearth box Th e wate r enters at i and passes out at k

-

At the back of
.
, .

th e tuy e re p late i s the wi nd box b

-
Th e blast enters thi s at a and p asses -

, .
,

through th ree wrough t i ron tuyere nozzles d (from I to 1 16 i n i n di amete r) i n -

, .
,

tuyere h oles m i nto the hearth at from 1 to 3 i n above the level of the lead
, , ,
. .

The h ood p lace d over th e furnace to carry ofi th e fume s and gases i s not shown
i n th e drawi ngs .

Th e work i n the Am eri can ore hearth i s conti nuou s as di sti ngui shed from -

th e Scot ch h earth Thi s i s m ade po ssi ble by wate r cooli ng the Si des of the fur
.
-

nace an arrangeme nt whi ch p ro te ct s the casti ngs and the tuy ere s
,
The fue l .

used i s wood charcoal and bi tumi nous coal Data are assembled i n
, ,
.

Tab le 3 2 .

5 T he .M o et Ore hearth
fl
1
( Fi g s 76 to — I n Fi g s 76 an d 77 t h e -
. .

1
W illi ams , Indust ri al Rep ort, Geologi cal Survey of M i ssouri , 1 8 77, p 36 : Tr A I . . . . M . E
1 8 76 7 7. v, 3 2 4
-

1
Broadh ead, Geologi cal Survey of Missouri ,
1
—
8 73 74 , p 4 9 2 . .

1 D ewey , Tr A I . . . M . E .
,
1 —
889 90 , XVIII , 6 74 .

Clerc, E ng M i n J 1 885, X L, 4 . . . .

m
Ra say, S ci entific A eri can S upplement, May 1 4 , 1 88 7, N o 59 3 m . .

“
Holi baugh, Lead and Zi nc i n Missouri , NewYork , 1 89 5, p 3 7
”
. .
102 ME TALLURG Y OF LE AD

furnace i s seen to rest on four pi llars The basi n) i s not set

. hea rth box (lead
-

i n bri ckwork and the lead i s thu s kept cool

,
Tw o f urnace s are set b ack to .

back the fumes passi ng ofl under one hood The lead runs through a separate
,
.

spout near the top of the wo rk sto ne i nto a cast i ro n ket tl e 3 1 i n i n di ameter
- -
.

and 44 i n deep not S hown i n the draw

.
,
i ngs It i s set i n a cast i ro n cyli nde r and .
-

heated from below one cord o f wood a week bei ng requi red for the p urpose
, .

The two furnaces work i ndependently On the floor of the lead b asi n t ests the .

FI G 79
m m
.
‘
AIR BOX ( v rec

S cal e X Inch -
1 1000

SECTIO N. S H O W ING TUYERES

FI GS —M ofi et ore hearth
.
76 to 79 .
-
.

parti ti on box havi ng an openi ng near the bottom for the lead to enter It
-

, .

serves as a suppo rt for the water box whi ch coo ls t h e hottest part of t he fur
-

nace and upo n whi ch re sts the ai r box co nsi sti ng of two separate chambers
,
-

( g
F i . w he re the heated blast passes down through the water box by means -

of fourteen I i n copper tuye re pi pes seven on ei t her Si de The worki ng ope n

-
.
, .

i ng i s 1 5 i n hi gh. A No 5 Bake r b lowe r fu rni shes the blast

. . The fuel used .

i s bi tumi nous coal .

The combi ned use of wate r and ai r coo li ng i s to prote ct t he casti ng i n con -
 104 M E TALLURGY OF LE AD

and b ul k of the fume by means of a sucti on fan and an outer for rem
th e ov ,

i ng the remai ni ng fume by natural draft Such a f urnace i s shown in Fi g 98 . . .

7 Th e . N ew nam M ech a ni c a l Ore hearth

1—
Th e i de a of rep lac i n g th e a rdu -
.

ous and unh eal t hy hand labor at the ore h earth by some mechani cal devi ce - -

has been held by many ope rators For example B rown patented a devi ce
’ 1 .

whi ch however di d come i nto practi cal use The onl y successful apparatus
, ,
.

so far i s th at of N ewnam constru cte d at the work s of the St Lo ui s Smel ti ng .

Refini ng Co Colli nsvi lle Ill put i nto operati on there and S i nce adopted by
.
, ,
.
, ,

—
other plants It i s sh own i n Fi gs 83 9 7 Fi gs 83 and 84 gi ve a front and si de
. . . .

ele vati on of the furnace ; Fi gs 85 and 86 hori zontal and ve rti cal secti ons of the .

lead basi n ; Fi gs 87 89 elevati ons and se cti ons of the mi ddle water j acke t ;
—
.
-

.
—
Fi gs 90 9 2 elevati ons of the ri gh t and left end j ackets and secti on of th e ri ght -

-
—
end j acket ; Fi gs 93 9 5 detai ls of the cast i ron stand suppo rti ng th e lead basi n ;
.
-

and Fi gs —
6 9 7 perspe cti ve vi ews of the furnace wi th rabbli ng me ch ani sm at
9 .

begi nni ng and end of tri p .

The b asi n a Fi gs 85 and 86 i s 8 ft long ,

i n wi de at the top and 1 0 in
,
.
, .
, . .

at the bottom and 1 0 i n deep ; i t has a verti cal b ack and a slopi ng front
, The . .

si de s of the fu rnace are cast i ron w ater j ackets p rovi ded wi th lugs whi ch fit - -

i nto si milar projecti ons of the basi n There i s a mi d dle j ack et b Fi gs 87 89 .

, ,
.
-

3 ft . i n l o ng and 1 8 i n h i gh w h i
. ch ha s a w a te r sp ace 4 i n w i de a nd e i gh t .
,
-

,
.
,

tuyeres 1 % i n i n di ameter The ri gh t and left si de j ackets c Fi gs 90 and

, . .
-

, , .

9 1
,
a re ca s t i n one wi th the end j acket s d shown i n elevati on i n Fi g 9 2 Th e -

, , . .

ri gh t and left j ackets e ach hav e four tuy e res m aki ng for the furnace a total of ,

1 2 t uye res From the basi n a Fi g 85 t he lead i s di scharged i nto the molds of
.
, ,
.
,

a mol di ng car Fi g 96 th rough th e si p hon tap e Fi g 85 ,

.
, , ,
. .

The i nner and outer h ood s Fi gs 83 and 84 are the same as those to be di s ,
.
,

cu sse d i n co nne cti o n wi th Fi g 98 Detai ls of the cast i ron frame supporti ng . .

-

the lead basi n are clearly shown i n Fi gs 93 9 5 — . .

The furnace wi th th e me chani cal rabbli ng devi ce i s repre sented by the

perspe cti ve i llu strati o ns Fi gs 96 and 97 beca u se a comprehensi on of the details ,
.
,

requi res a large number of drawi ngs whi ch are out of place here The rabbli ng .

machi ne i s hung from an overhead traveli ng carri age 3 ft long wi th a gauge ,

.

of 3 ft 1 0 i n The steel frame supporti ng the carri age i s 1 4 ft 6 i n by 4 ft

. . . . .

i n and 7 ft 8 i n hi gh
. Assu m i ng th at the carri age i s at rest at the ri gh t
. . .

end of the hearth Fi g 96 a lever i s pu lle d to st art the m achi ne on i ts p ath to ,

.
,

the other end du ri ng whi ch the rabble armi s gi ven a moti on si m i lar to that of -

the h and rabble When the rabble armi s wi thdrawn from the fire the era
-
.
-

ri age moves forward a di st ance of 4 i n and starts the armon the ne x t strok e .
, .

When th e carri age has arri ved at the oppo si te end of the furnace Fi g 9 7 i t i s ,
.
,

stopped automati cally the rabb le armi s w i th drawn and the carri age ret urned ,
-

to i ts ori ginal po si ti on In Fi g 97 i s Shown a 1 h p motor whi ch i s connected . .

-
. .

t hrough geari ng wi th th e m ai n shaft Thi s carri es at i ts left extremi ty a .

1 Tr A I . . . M . E .
, 1 91 6, LI V, 4 85 . Pri vate Notes J uly , ,
1 9 6.
1

1 Tr A I . . . M . E .
, 1 91 1 , X LII , 4 0 2 .

1
U S Patent No 88858 2
. . . . May 2 6 , 1 908 .
S MELTI NG LE AD ORES I N TH E ORE -
HEARTH

Cas t -
Iron S tand

FI GS 83 to 9
.
5.
— N ewnammechani cal ore hearth
-
.
106 ME TALLURG Y OF LE AD

r k pulley to
c an -
attached the rabble arm
whi ch i s ; the latter i s-
supp ort ed by a

rest and thrown i n or out of acti on by means of a tooth cl utch The mai n sh aft
-
.

carri e s a sp rocke t whee l w

-
hi ch rotates by means of a chai n a counter sh aft i n -

FI G 9 6
.
— Rabbl i ng
. machi ne at begi nni ng of tri p .

FI G 9 7
. .
— Rabbli ng machi ne at end of tri p .

t he ca rri age ;
the la tter h a a
s toot h ed cl ut c h a n d dri ve s by m ean s of a be ve l
gear F,
i g 97 .one,
ax le of t h e car ri a ge w h e n t hi s i s to move f rom ri g h t to left.

Th e m h f
ai n s a t ca rr i e s als o a n e x c e ntri c F i g 9
,
6 .w hi
,
ch i s co nn e cte d th roug h
three levers ( one strai ght and two angle ) wi th a ratchet and pawl to dri ve the
108 M E TALLURGY OF LE AD

posed ore The former i s

.
(someti mes i nto a water box) ; th e latter
thrown asi de -

goes back to the furnace slaked li me bei ng spread over i t if necessary Any
, , .

slag adh eri ng to the tuyere s i s th en removed ; some fuel i s di stri buted i n front

of them and over the charge ; fresh ore i s Spread on the fuel and thi s agai n ,

cove red w i t h fine fuel ; the n all i s ready for a second operati on As the
'

smel ti ng p ro ceed s th e bulk of th e lead that i s set free tri ckle s th rough the cha rge
,

i nto the h earth box and overflows through th e groove i n the work stone i nto
- -

the kettle H e re i t i s someti me s poled before bei ng ladled syph oned or drawn
.
, ,

ofi th rough a spout i nto molds Some lead passe s ofl wi th the f umes and the.

rest goes i nto th e Slag .

P atti nson calls attenti on to the follo wi ng poi nts i n managi ng the ore hear th
1 -
.

Th e amount of blast and i ts di stri buti o n t hrough the enti re charge shoul d be
car efully regulated t he half re du ced ore Should be expo sed on t he wo rk stone to
,
- -

the oxi di z ing acti on of the ai r and the addi ti ons of li me and fuel ju di ci ously made
,
.

Wi th Ameri can ore hearth s the blast i s not shut ofl every 3 to 5 m

-
in .
,

but works conti nuou sly and the process i s therefore not i nterrupted The
, .

first step i n normal work i s to spread a few shovelfuls of coal over the fire ,

and then five or Si x shove lfuls of ore mi xed wi th from 0 5 to per cent . .

li me . The fire i s left undi sturbed for from I to 1 5 m i n duri ng whi ch ti m e . .

,

the charge i s more or l ess oxi di z ed the flame b reaks th rough and the surface , ,

of th e charge becomes i ncru sted The poker i s thrust by the charger over the .

edge of the basi n i nto the lead and th e sli ghtly caked mass li fted and loo sened, .

H e begi ns at one say the ri gh t end of the furnace and pro ceeds Slowly to the
, ,

left. At the same ti me the helper followi ng hi m p i cks out w i th a shovel , ,

glowi ng fumi ng lump s (gray slag) that have been formed places them on t he ,

apro n and then to sses them i nto th e water box

, The helper nowe xch anges t he -
.

shovel for the pad dl e and loo sens th e fire a se cond ti me whi le th e charger fol ,

lows hi mand pi cks out newly fo rmed Slag wi th the shovel Lastly the paddle .

i s lai d asi de and the shovel u sed to remove i nost of the remai ni ng Slag
, When .

thi s i s done newcoal and newcharge are fed The whole operati on lasts
, .

about 2 m in The m . en rest from 1 to 1 5 mi n duri ng whi ch ti me the charges . .

,

become partly oxidi zed and caked .

The charge i s made up of ei ther galena alone or a mi x ture wi th sintered bag

house fume Formerly slaked li me was used exclusi vely as flux ; wi th the t e
.

placement: of bi tumi nous coal by coke breez e the greater heat generated by -

the combusti on has permi tted th e use of li mestone whi ch works sati sfactorily ,

under the newcondi ti ons Th e amount of fuel used ranges from 4 to 8 per cent
. .

of the ore mi x tu re .

The wo rk i s very exacting as i t i s e ssenti al for su ccess that th e charge ,

remai n open i n o rder t hat th e blast m ay easi ly penetrate al l p arts Usuall y .

there are employed two men to a hearth on an 8 hr Shi ft ; at Granby there work -
.

four men on a Si ngle shi ft of 9 hr one pai r reli evi ng the other at Short i ntervals .
, .

The better the sti rri ng the larger i s the smel ti ng power of a furnace and th e
, ,

greater i ts producti on In most plants the amount of metalli c lead produced

.

1
Percy, “Lead "
2 88.
, p .
 S MELTI N G LE AD ORE S I N TH E ORE -
HE AR TH

by a crew duri ng i ts Shi ft i n summer i s lower than that in wi nter Thus from .
,

t he normal amount of lb ore to be worked per shi ft of 8 hr the m . en .

,

ex tract 50 per cent metalli c lead i n summer while i n wi nter th e figure may
.
,

reach 60 per cent .

The lea d set free i n smelti ng si nk s through the fire and coll ects i n the basi n .

In o rder to make i t overflow freely through the channel i nto th e coll ecti ng pot -

the S hovel i s forced through the charge i nto the lead and th en moved up and
down a pumpi ng moti on whi ch rai ses the lead and causes i t to flow readi ly i nto
,

t h e h
c a n n e l In t e pot
h . th e lead s drossed and then cast i nto 80 O r 1 00 lb
i — .

bars ; t he dross goes back to the furnace The lead i s cleaned by li q uati ng .

and po li ng and i s th en cast i nto market b ars unless i t i s to be desi lveri z ed as

, ,

at Co lli nsvi lle and Federal I II ,

.

Th e mode of operati ng wi th the N ewnam mechani cal ore hear th i s the -

sa me as th at i n a hand worked h earth except that t he sti rri ng i s done by m-

a

chi n ery as sh own i n In a comparati ve test of 4 weeks durati on wi th

’

a gal ena co ncentrate assayi ng Pb and S per cent the N ewnam 8 ft .

,
-
.

ore h ea rth trea ted

-
lb ore produced 644 3 lb p i g lead and 331 8 lb gray.
, . .

slag ( Pb FeO Cao S Inso l per cent ) used p e r ce n t . .

co ke breez e
-
and made , rabble tri ps per hour The figures for the 4 ft -
.
-
.

hand ore he arth were ; ore 509 1 lh p i g lead 2 030 lh gray slag 1 3 2 9 lb
-
.
,
.
,
.

( Pb F eO C aO S I ns o l per c oke bree z e -

per cent Of 1 00 lb lead i n the ore the N ewnam hearth recovered

. .
,

as p i g lead as gray Slag and

, as dust and fume ; wi th the hand ore
,
~

hea rth th e figures were p i g lead gray slag ,

dust and fume
In the gray Slag produced by th e parallel tests the lead w as pre sent as PhSO. ,

PbS 6 PhO , Pb total per cent Du st and fume were fo rmed .

i n th e p roporti ons of 1 lb d ust to 2 lb fume Th e dust assayed Pb

. and . .

S per cent ; the lead i n i t was di stri buted as PbSO .

. PbS PhO
per cent The bu rnt fume assayed Pb . and S per cent the lead ,
.
,

bei ng di stri buted as PhSO . Pbs and PhO per cent The .

S eli mi nati on wi th the N ewnam hearth w

-
as per cent wi th the hand .
,

h ea rth per cent .

T rea tment of a gal ena concentrate wi th Pb and S per cent gave .

p e r 8 h r -
sh i ft
. th e fo ll ow i n g fi gu re s ore lb p gi l e ad 1 0 79 0 1b gr ay
,
s la g .
, ,
.
,

1 0 7 5 lb coke breez e
.
, per cent cru shed li mesto ne
-

p er c e n t T h e
.
,
.

p e rc e n ta ge of l e ad r e covered i n t h e produ cts w a s i

p g l ea d gr a y s la g ,

d ust and fum e per cent ; the S eli m i nati on w as per cent .
-
.

Smel ti ng flue dust ( Pb 62 per -

pugged wi th li me and burnt bag house ,
-

fume ( Pb 76 per . and mi x ed to co ntai n 76 per cent Pb and usi ng 1 0 .

,

p e r ce n t c oke .b re e ze to m a ke-
U p f o r th e la c k of su lp h u r g a ve a s i
p g l e a d ,

per cent of th e Pb charged as gr ay slag (Pb

. FeO ,
CaO S
Insol . per cent ) 1 0 per cent and as fume . per cent .
,
.

Th e yi eld i n p i g lead and the eli m i nati o n of sulphur are greater i n the N ew
namthan i n t he hand h earth the wo rk i s easi er and less unwholesome and the , ,

co st a gre at deal le ss .
1 10 M E TALLURGY OF LE AD

68 Plants
.
— In modern plant the hearths usually stand separately i n a
. a

Si ngle row i n th e hearth bu i ld i ng In front and b ack are track s on th e front track
-
.
,

arri ve concentrates fuels and flu xes to be empti ed i nto wooden boxe s or bi ns ;

, ,

on the back track are taken away on tru ck s the b ars of lead and i n cars the gra y ,

slag . Back of a row of fur naces runs the blast mai n from whi ch branch pi pes -

deli ver the ai r to the fu rnaces On the left si de of a furnace i s a branch track .
-

for the slag car and on the ri ght th e lead pot and frame to suppo rt the mold s
-

,
-
.

E ach h earth has a small i nner hood w hi ch rests on the si de j acke t s and i s con -

nect ed wi th a fan and a large oute r hood whi ch carri es 03 by natural draft th e
,

fumes ari si ng from the gray slag and other gases The stove pi pe whi ch form s
, , .
-

the chi m ney for the fireplace of the lead pot exte nds i nto the outer hood and -

thus fu rni shes the necessary draft .

The gase s from a rowof furnaces p ass ei ther i nto a dust chamber and the nce -

i nto the m ai n flue or go di re ct i nto the mai n flue whi ch se rves as du st

, ,

chamb er Th ey travel then through a seri e s of i nverted U shape d pi pes ( goo se

.
-

whi ch cool the gases and cau se the large r part of the dust to settle and ,

enter th e sucti on fan Thi s draws the gases from the furnaces thro ugh th e.

coo li ng and settli ng devi ces me nti oned and deli vers th em to th e bag ho use , ,

where the remai ni ng dust and all the fume are filtered In plants whi ch smel t .

t he gray Slag from th e ore hearth w i th the si ntered bag house product i n an - -

ordi nary blast furnace for lead mat te and slag the gase s from the blast fur , , ,

nace u su ally ente r the m ai n flue of t he ore h earth near the fan and are fil tered -

, .

B y thi s m anner of operati ng the lo sses i n lead have b ee n reduce d to a tota l ,

of 2 p er ce nt .

Tab le 3 1 by P ulsi fer gi ves the leadi ng facts of the condensati on plant s of
1

five modern ore h earth smelteri e s -

.

T AB LE 3 1 .
— CO LLE CTIO N or ORE -
EE ARTII F m

I 1 794

Hearths Hearths Hearths

and blast
furnace .

Fan, k1nd Bufl alo B ufi alo Bufi alo

Fan, di a m in .
, 90 x
Bag house material above bri ck
cellar .

Bag house, si ze, ft

Bag house, co mp artment N s o

Bag house, cellars

Bags, N o .

Bags,
Bags, si ze, in x .

1
Mi n . E ng . World, 1 9 1 4 , XL, 0
5 2.
1 12 ME TALLURG Y OF LE AD

from whi ch branches f and j deli ver to the furnaces The water mai n g wi th
,
'
,
.
-

, ,
’ ’
branches g and g furni shes coohng water to the j ackets The gas mai n h
,
-
.
-

, ,
’
wi th gas i nl et pi pes i and i deli vers du st through outlets j i nto hoppe rs k
-
, , , , , ,

provi ded wi th gates I from whi ch i t i s di scharged i nto ears n A hearth has
, , , .

two hoods The i nner hood 0 placed di rectly over the hearth earri es dust
.
, , , ,

FI G 8 — H and ore h earth, Colli ns vill e, Ill

9
-
. . .

fume , and gas th rough pi pe , i , i nto gas

mai n h ; the outer hood p attach ed to t h e -

, , ,

i nner draw
,
s stray fume s aw ay from the furnace m en i nto the ope n th roug h a -

Sheet i ro n stack g 36 ft hi g h measu red f rom the fu rnace floo r

-

, , .
-
.

Tw o m en wo rk i n an 8 hr shi ft Coke to the ex tent of 4 to 5 per cent serves

-
. . .

as fuel ; no li me i s used A hearth tre ats i n 8 hr 7000 lb concentr ate and

. . .

r odu ce 62 00 lb p i g lead whi ch is approxi m ately 55 per ce nt ; of the remai nder

p s .
,
.
,
 S ME LTI NG LEA D ORE S I N TH E ORE ’
-
HE ARTH

16 per cent goes i nto gray slag and the rest ( 2 9 per cent ) i nto dust and fume
.
, .

colle cted i n th e bag hou se .

Th e ore hearth and blast fu rnace le ads we re fo rme rly softened togeth er for
-

1 2 h r i n a reverbe ratory furnace wi th hearth 1 8 by 1 1 ft and 1 6 i n deep

. . .
,

holdi ng 1 2 0 tons lead and fire box 8 by 1 2 ft ; the firebri dge w as water coo le d
,
-
.
-
.

Th ere were produ ced 2 5 p er ce nt dro ss and 1 p er cent ski mmi ng At . . . .

present the lea d i s cleaned i n two 5 ton kettles and desilveri zed by the P arkes -

process i n four 60 ton kettles The de sil veri zed l ead i s freed from -
.

Zn i n 1 2 hr i n two reverberato ry furnaces ( hearth s 1 0 by 1 3 ft ; fire b oxe s

.
, .
-

2 by 7 ft ) each holdi ng 55 tons tapped i nto corre spo ndi ng poli ng kettles and
.
, ,

si ph o ned i nto molds resti ng on a casti ng wh eel ( See also Tables 3 1 and -
.

4 G ra n b
.
y M — T h e o re a ga l,
e n a c o n c e nt ra te m i x ed w i th si n te re d fume , ,

i s smel t ed i n five ore h earths 4 ft lo ng 1 5 i n wi de and 1 0 i n deep provi ded -

,
.
,
.
, .
,

wi th wate r j ack ets 1 2 i n hi gh A furnace has four tuyeres poi nti ng downward ;
-
. .

the ap ro n pl ate i s 1 8 i n wi de The furnaces are wo rked only duri ng the day . .
,

fro m 6 a m to 4 p m; four men tend a furnace two worki ng at a ti me for

. . . .
,

20 m in At 6 a m a charcoal fire i s made on the fro zen lead i n the b asi n and
. . .
,

co al added ; at 7 o clo ck the lead i s li quefi ed and h eated N owore mi x ed wi th

’
.

li me i s spread over th e glowi ng fire and wo rked i n the u sual w ay o nly wi t h ,

mo re vi gor and more coal Ai r blast on the floo r and hi ghe r up serves to keep .
-

th e m en cool Th e blast pressure for the fu rnace i s from 6 to 8 oz ; th e hi gher

. .

p ress ure i s used wi th oxi de ore prevai li ng A furnace treats duri ng the day .

l b ch arge requi re s 2 bu li me co nsumes

.
, lb coal extracts 75 p er ce nt .
,
.
,
.

of t h e lead as metal makes 2 000 lb gray Slag wi th 4 0 p er cent Pb , 1 0 p er . .

ce nt of the lead of the charge) whi ch i s so ld and

. lb fume w —
i th 55 60 p er , .

ce nt Pb . 1 5 p er ce nt of the lead of th e charge) ( See also Table s 3 1 and . .

5 W e bb. C i ty M — T h e o re a ga l e n a c o n ce
,
n t r ate w i t h 8 0 per ce n t Pb , .
,

i s t reated i n Si x ai r cooled ore hearths standi ng i n a row each cove red by a - -

S i ng le h oo d e ndi ng i n a pi pe provi ded wi th a damper Th e pi pes lead i nto a .

mai n connected wi th a fan A hearth i s 60 i n long 1 8 i n wi de and 7 i n deep . .

, .
,
. .

T h e fuel u sed i s coal Tw o m en te nd a fu rnace i n a 6 hr shi ft . Between -

. .

shi f t s t h e lead i s allowed to freez e E ach Shi ft treats 7000 lb ore mi xed wi th . .

4 00 l b li me O. f t h e le a d i n .t h e o re 6 5p e r c e n t i s re c ove red i n t h e h e a rt h a n d , .
,

34 p e r c e n t i n th e b las t fu r
. n a c e T h e l e a d i s re me l ted i n a kett le h o ld i ng 99 00 .
-

l b pol ed and drawn ofi i nto mo lds whi ch re st on a car traveli ng on a track

.
, , .

Th e plant w as i dl e i n 1 9 1 4 .

6 J opli n M o
.
— The plant of the Lone E lmworks are taken up i n § 7o
, . .

7 G a l et.ta O n t A n e w p la n t w i,
t h t h e N ewnam ore he arth h as bee n put i nto
.
- -

op era ti on at Gal etta Ont Th e plant i s shown i n plan elevati on and se cti on
3
, .
, ,

Perki ns , E ng Mi n J , 1 907, XXX IV, 388

'
1
. . . .

B usk et t, Mi n Eng World, 1 908 , XX I X , 9 1 7 . . .

Pulsi fer, o p . ci t. , 1 9 1 4 , XL, 4 50, 50 1

Mi n E ng World 1 9 1 0 xxxm 1 04 7
.

1
Ruhl , . .
, , , .

Wi tti ch M i nes and Mi neral s 1 9 1 1 XXXI 709 wi th

, , , , , p lan of works ,
1
Newnam, Bull A I M E April, 1 9 1 7, 4 2 5 , . . . .
,
.

8
1 14 ME TALLURGY OF LEAD

i n Fi gs 99 o t
. the hear th house wi th a Si ngl e h eart h 8 ft lo ng ;
-
1 01 . It c n ai ns -

, .

a dro ssi ng kettle wi th moldi ng appara tus ; and th e ne cessary bi ns for ore coal , ,

and coke The gases from the hearth pass through four goo se necks p lace d in
.
-

parallel i n whi ch the temperature i s gre atly reduced ; travel through a ball oon
,

flue 300 ft long provi ded wi th di scharge hoppers ; enter a No 1 0 Si rocco

.
-
.

exhaust fan whi ch deli vers 8000 cu ft per mi n at a temperature of no t over . . .

,

87 C to the bag house wi th 99 co tton b ags 1 8 i n i n di ameter and 30 ft l o ng

°
. . .
,
.
,

Th e dust from the goo se neck hoppe rs and flue system i s collecte d i n clo sed -

, ,
-

buggi e s pugged wi th li me and bedded wi th the galena concentrate and the

, ,

burnt bag house dust and fume The powe r requ ired i s 1 5 h p
-
. .

ELEVATION FLU E

ou H EART H HO US E
eecru
FIG . ” PLAN
FI GS 99 to . 1 01 . — Plan
,
elevati on and secti on, Newnam O re -
hearth Plant , Galet ta , O nt .

The treated i s a mi xture of 50 per cent jIg and 50 per cent tab le
ore . .

co nce ntrate averagi ng Pb I nsol Fe Cao Zn S per .

ce nt .and Ag
,
oz per ton The ore i s mi xed wi th from 2 to 3 p er cent
. . .

finely cru shed li me stone and about 3 p er cent coke b reez e ,

.
-
.

The h earth produ ce s daily about 1 5 to ns of lead The le ad co ntai ned i n the .

produ cts i s p i g lead 74 per cent gray slag 1 2 and dust and fume 1 4 p er cent
,
.
, , .

The p i g lead assays Pb Cu p e r ce nt an d Ag oz per t on ; th e .

,
.

gray slag Pb Insol FeO ,

Cao S per cent The Slag i s
. .

stored and shi pped when e nough has bee n accumulated The lead lo ss i s I 5 .

per cent The hearth i s worked by two men on a Shi ft ; there are 1 4 m
. en i n the

plant .
1 16 m ALwm T Y W L mD
s
A
A
Q
3 S 3 3
A
3 d
v : 5

0 c a

e o o o o o

0 0 0 0
0 8 ° 0 g 0 3 .
0
0
0
0

u u u n n n e
o ww u
o n u

w
“ “ a G u c “ p
u
Se
0 o
8 o o
“ 3 s
w d
“e a e d

—
a
0 3 c
s o
i
m
e E E c 0 0 . e c n
n
i m a
.

x u
a
c S S o
7 7 o
0 n
- e u b
o
m T T
e 8 8 a m Sa d mgo 0
a
fi
é
e
a i u
A
- - d
9
3
o -
d 3 3 s a a l

3
s m «
.

n
“
c h -

fi
w 0 0 0 B3 3 k ? ar k . . . B

H N H H N H N N H

2
2
36
B
3
a s
m3 0
2 c aO
“
G

w
e

5 a z
.

m s
o z
a z s
as 0
o
S $ 0 w 6
o
m
m
s
s o —
0e
s
k
o
a 9 B h
a
fi S 3
mE 0 e
n
o n
5 Bm
a m
o

mm
0 :
a n c z e 2
o c s o o h 6 -
o o 9
s d o 0 Bh o e6
 S M ELTI NG LE AD ORE S I N TH E ORE -
HE ARTH
T AB LE — AN ALYS E S or GR AY S LAG
33 .

1 . Sext on E ng . . Mi n J . 1 89 5 , LIX , 1 75 .

2 . Dewey Tr A I M E , 1 888 9 0 XVIII 6 8 5

, . . . . .
-

, , .

3 . f
Pul si er M i n E ng World. 1 9 1 3 , XX IX . 68 1
, . . .

metalli c lead alone was formerly carri ed on i n a small low

S mel ti ng for 1

bri ck b last furnace ( 2 6 by 36 i n and 4 6 i n hi gh) wi th a si ngle 3 i n tuy ere at the

-
. .
-
.

back an external cru ci ble and a hood to carry off fumes i nto the open The
, ,
.

cruci bl e w as a cast i ro n pot di vi ded i nto two unequal part s by a parti ti on -

descendi ng nearly to the bottom The melted charge (black slag) flowed over .

t h e larger di vi si on filled wi th charcoal i nto a water tank the lead fil tered , ,

-

th rough the charcoal collected at the bottom and was removed at i ntervals , ,

from t he smaller di vi si on As the bri ckwork w as qui ck ly co rroded a furnace .

,

ran only a Sh ort ti me From 1 5 to 1 8 tons slag assayi ng 3 5 40 p er cent Pb — .

.
, ,

were smelted i n 1 6 hr gi vi ng lb lead whi ch w as not soft and waste . .

, ,

slag; the fu el co nsum pti on was 2 tons coke and 2 2 bu charcoal . .

Thi s mode of operati ng bei ng w asteful and expe nsi ve has been replaced bv , ,

norm al blast furnace wo rk Th us at Colli nsvi ll e Ill there are three water
1
. .
, ,

j a cket b la s t fu r n a c e s 3 6 by 1 2 6 i n a t tuy e re s i n w hi ch a r e t r ea
,
ted i n 2 4 hr .
, .

from1 2 0 to 1 40 to ns of charge made up of gray slag i gni ted bag house fume ,
-

roas ted m atte dro sse s and re fini ng ski mmi ngs from the Parke s desilveri zi ng
,

p l a nt fl u e d u s t b
, ri quette s an-
d flu x e s T h e Sla g m a de a n al y se s $ 10 2 FcO ,
.

Cao per cent The gases from the blast furnace s go through the .

bag house .

At Federal Ill there are also three water j acket blast furnaces 40 by 9 6
1
,
.
- -

i n at tuy e res
. The ch arges are mi xture s of gray slag i gni ted bag house fume
.
,
-

blast roasted ore roasted m atte and pyri te ; they co nta i n 40 p er cent Pb and , ,
.
,

g i ve a m a tte fa ll of 1 7p e r ce n t Th e
-
s la g i s c a lc u la t ed to c o n ta i n $ 10 3 3 2 FeO .
,

3 0 —
3 2 C a M
( g) O 1,6 — 1 9 Z nO 8 A 12 0 ; up to 9 p er c e n t ; i t a s s a y s ,
per ,
.

ce n t Pb . .

O ther works whi ch u sed to smelt thei r gray slag i n small ci rcular blast
furnaces find i t more profita ble to sell i t to blast furnace plants
,
.

Smelti ng of gray Slag wi th other ch arge compo ne nt s for m etalli c lead -

o xi di zed lead fume and waste slag i s consi dered i n § 72 ,

.

3 F lu e du s.t a n d F um e — T h e
-
g as e s drawn f rom the ore hearth by a powe rfu l -

s u cti on fan carry du st and fume ; th e large r part of t he fo rme r settle s i n t he

ch a m ber and flue leadi ng to the fan the rest i s filtered wi th the fume i n the ,

1
Bergen, Co mmi ssi oner Raymond ’
s Report, 18 75, 4 2 4 .

1
Pulsi fer, Mi n . E ng . World ,
1 9 1 3 , XXX IX , 68 1 .

1 Pulsifer, Mi n . Eng . World, 1 91 3, XXXIX , 3 75 .

1 18 ME TALLURGY OF LE AD

bag house and c

ollected i n the bri ck bays of the buildi ng The dust consi sts .

mai nl y of fine parti cles of charge whi ch may or may not have been o xi di z ed ,

the fume almost enti rely of o xi de lead compou nds Th e ch emi cal analyses .

gi ven i n Table 34 Show the characteri sti cs of the two pro ducts .

TAB LE — AN ALYS E S or ORE BE ARTR D U ST AND FUIIE

34
-
.

Lone E l mM . o.

h m
C a ber dust -
2 76 22 74 3 9 3 0 06 6 4 0 03 3
Fl ue 2 54 10 39 1 1 9 7 0 05 5 2 4 O3 1 3 5 none
Duet from c oo l i ng

p
ipe 27

Ra w or bl u e

f um e

Ro w of bags I , h op Zn
p er : 0 17 3 4 44 44 0 10 0 10 0 2 1
R o wof baga a h op
p er 6 o 1 1 ro s7 o 3 4 43 . .
5 5 44 4 8 o o 19 0 13

Ro wof bags 4 h op .

p ar ! o 12 88 4 5 08 07 0 07 0 03 o 26 0
. . 68
Ro wof bags 4 h op .

p er I o . 00 08 0

Si nt ered fum e o 10 4 8 76 4 6 32 0 3 7 0 90 I

Coll i nsvi lle. I ll Fe

Ra wfu me .
s o 2 5
J opl i n . Mo .

Ra wor blue fu ma . o 24 4 63 4 7 68 4 2 52 0 52
Burnt bl ue fu me .

1 . Dewey Tr A I M E . . . . . 1 889 -

9 0. X VIII . 6 7 4 .

2 . f
Pulsi er, Mi n . E ng . W orld . 1 9 1 3. xxx xx . 68 1 .

3 . Baskett , Mi n . E ng . World . 19 1 2 . XXXVI . 393 .

The mber and flue dust ha ve to be agglomerated before they can be

cha -

su cce ssfull y smel te d Some wo rk s resort to b ri quetti ng w i th slaked li me .

othe rs to si nteri ng others add the dust to blast ro asti ng charges ; mo i steni ng ,

the dust and addi ng i t to the blast furnace charge i s an inefi ci ent method of
hand li ng .

Th e fume w as fo rme rly allowed to go to waste In 1 876 the Lo ne E lmwork s .

of Jopli n Mo began to filter and convert i t i nto a whi te pai nt ( Subli med Lead)
,
.
,

by si nte ri ng and the n smelti ng wi th gray slag i n a slag eye furnace for lea d -

slag and fume whi ch w

,
as collecte d i n a bag hou se .

Th e plan of t he fo rme r Lone E lmwo rk s i s shown i n Fi g 1 02

1
The gase s . .

from the ore hearth are drawn off by a sucti on fan 6 ft i n di ameterand 3 i n wi de
-

,
. .
,

maki ng 2 90 pass through a wate r j ack eted b ri ck flue i nto a bri ck du st -

ch ambe r ( 40 ft lo ng 1 9 ft hi gh 6 5 ft wi de wi th a doo r on one si de) wh i ch col

.
, .
, . .
,

lects co arse p arti cle s of mo re or le ss changed ore and fue l ; leave the chamber at
the top and travel through a hori zontal sheet i ron pipe (3 50 ft long 5 ft i n di am -
.
,
. .
,

suppo rte d by 2 o ft pi llars) to t he fan ; and th e nce through a 4 ft pi pe re st i ng on

-
.
-
.
,

1 2 ft pi lla rs to the b lue powde r or bl ue fume bag hou se

-
.
, Thi s first bag h ou se - -
.

i s Si milar i n const ructi o n to th e seco nd the whi te pai nt bag house Shown in ,
-

1
Dewey ,
Tr A I . . . M . E .
,
—
1 889 9 0 , XVI I I , 6 74 .
1 20 ME TALLURGY OF LEAD

holes, 1 di amete r from whi ch thi mbles 1 2 i n hi gh project up ward

8 in i n .
, , .
, .

O ve r th ese th e lower e nds of th e b ags made of u nw ashed wool 60 i n i n ci rcum

, ,
.

ference and 33 ft lo ng ( changi ng to 50 i n and 3 5 ft when i n use) are sli pped

. . .
,

and ti ed fast The upper ends are ti ed wi th strong cord wi th whi ch th ey are
.
,

suspended from beam s near the roof There are 800 b ags i n the bag hou se
. .

B etween every two rows of bag s i s an i ro n scaffoldi ng wi th i ron footways placed

at co nve ni e nt hei gh ts so as to m ake all p art s of the bui ldi ng acce ssi ble
, .

Fxo . 1 03.
— Secti on of bag house for w
-
hi te fu m
e, Lo ne ElmWorks, Jop li n MO , .

Th e oole d gases bei ng forced through the mai n pi pe enter four bran ch
c , ,

pi pes each of whi ch passe s through and connects a set of hoppers The gases
,
.
,

laden w i th fum e and some du st ascend i nto the hangi ng bags whe re they are
, ,

fil te red th e fumes falli ng i nto th e hoppe rs below

,
These are empti ed o nce i n .

2 days ,
when the b ags are also shaken to detach adheri ng fume For thi s .

purpo se the current of the gas i s shut off and men wi th aspi rators pass qui ckl y
,

through the bu i ldi ng gi vi ng each bag a qui ck sh ake

,
.

The colle cted fum e i s a very fine blui sh gray powder (blue powder) con-

si sti ng mai nly of PhO and PbSO l wi th some Pbs , .

T he fume i s someti mes sol d as Subli med Blue Lead to be used i n the manufa c
’

ture of rubber ( bl a ck tre ad) ti res, or as a p ai nt Usu ally however i t is let .

, ,
 S MELTI NG LEA D ORE S I N TH E ORE HE AR TH -
121

down from the h oppe rs spread ove r the floor i n pi les and set on fire wi th oil , ,

waste Often i t fires i tself It bu rns (smolders) for ab out 1 0 hr but does
. . . .

no t flame ; a good deal of h eat i s li be rated and some S02 set free The fine ,
.
,

l oo se blue powder i s converted i nto a po rous pi nki sh whi te cru st that i s still ,
-

fri ab le but sufli ci ently coherent to sta nd handli ng and chargi ng The roasted .

bl ue powder i s free from carbonaceous matter and PbS Analyses are gi ven .

i n T ab le 34 .

In refini ng the roasted blue powder i n the slag eye furnace the object i s -

to oxi di z e all the components of the charge as mu ch as possi ble ; hence li ttle
metalli c lead i s p rodu ced To prevent any carbonaceous compounds from .

i njuri ng the colo r hard 72 hr coke i s used as fuel Thi s subje ct i s di scussed in
,
-
. .

§ 72
— Th e cost of smelti ng 65 to 70 per cent galena concent rate i n
7 1 Cost .
-
.

the ore hea rth collecti ng fume i n bag house and smelti ng gray slag and
-

, ,

si ntered f ume i n the b last fu rnace for p i g lead m atte and slag i s about a -

, ,

t on 1
. The yi eld i n lead i s about 98 per cent Brown gi ves the cost at Granby
2
.
,

M o for smelti ng ore and si ntered fume i n the ore hearth ( the gray slag bei ng
.
,
-

so ld) as $3 30 per ton of lead bear i ng m ateri al

.
-
.

L w m
'

7 2 e i s an
. d B a r tlett or S ubli ed L ea d Pro ce ss '
Thi s pro ce ss w hi ch -
.
-

was started at Jopli n Mo i n 1 876 i s i n operati on i n the Uni ted States at two ,
.
, ,

plants that of the E agle P i ch er Lead Co Jopli n Mo and that of the St

,
-
.
, , .
, .

Loui s Smel ti ng Refini ng Co Alton Ill ; and i n E ngland at the wo rk s of the .

, , .

B ri s tol S ubli med Lea d Co ‘

.

The ai mof the proce ss i s to volatili ze the lead from gale na and the gray
sla g and burnt b lue powde r of t he ore h earth by smel ti ng i n the o xidi zi ng -

atmosp here of a slag eye furnace and to recover the oxi di z ed fume i n a -

bag house Th e produ cts are waste slag some m

. etalli c lead and so ca lled , ,
-

sub li m ed lead a finely di vi ded whi te powder wi th about 80 p er cent PbSO 4

, .

and 2 0 per cent PbO whi ch i s u sed for pai nt the manufacture of oi l cloth .
, ,
-

stai ned paper and rubber goo ds , .

Th e two Ameri can smelteri es are very si mi lar i n thei r ge ne ral arrangement s .

A plan and elevati on of plant are shown i n Fi gs 1 04 and The bri ck .

bui ldi ng 2 1 5 ft long and 75 ft wi de has four di vi si ons : ( 1 ) Th e furnace

,
. .
,

room 75 ft
,
lo ng w i t h two slag eye fu.rn ace s A a nd a si ng le c ombu,
st i o n -

, ,
’
chambe r above ; one large and two small coo li ng towe rs B and B ; two N o 7 -

,
.

Sturtev ant blowers H dri ven by two 3o h p A C motors to furni sh blast at , ,

-
. . . .

1
I ngalls, Tr A I . . . M . E .
906, XXXVI] , 6 2 9
, 1 .

Fi nlay, E ng Mi n J , . . . 1 908 , LXXXVI , 60 7 .

Tr A I M E , 1 9 1 1 ,
. . . . . XI 11 , 4 02
. .

Dewey ,
Tr A I . . . M . E 889 90, XVII I , 6 74
.
, 1 -
.

Blai r, E ng M i n J , . . . 1 9 1 0 , X C, 906 .

Hughes , J S oc Che . . m I nd . .
,
1 9 1 9 , XXVIII , 415 .

Busk et t , Mi n . E ng . World , 1 91 1 , XXXV, 5 7 ; 1 9 1 2 , XXXVI , 393 .

Schaefi er, J I nd Eng Che , 1 9 1 3 , v, 1 4 9 m

m
. . . . .

Roesi ng, Zt B erg H t en S al W i Pr , 1 888, XXXVI , 1 03

'

. . . . . . . .

Blai r, E ng Mi n J , 1 9 1 0, XC, 906 . . . .

1 22 ME TALLURG Y OF LE AD

43
6 oz . for the slag eye furnaces ; -
and one frei gh t elevator ,
I, dri ven by a 2 0 h p -
. .

AC. . motor .

( ) goo
2 se n e ck room
The 30 ft lo n g wi th seve
-
n goo se ne k C ; one 7 f t ,
.
,
-
c s, -
.

fan D dri ve n by a 5o h p motor deli very pi pe and sto rage space for cla y
, ,
-
. .
,
-

and othe r m ate ri al s .

( 3) Th e ba g room G 75 ft lo ng w i th de li ve ry p i pe J com i ng,

f ro m ,
go o se .
,
-

, ,

ne ck roo m w i th branch pi pes leadi ng i nto three rows of hoppers K nine -

, ,

hoppers i n a row each wi th 2 0 filter bags E ,

-

, .

E LEVATIO N

F1 03 . 1 04 and 1 05
— Elevati on and p lan of subli
. med lead p lant
-
.

(4 ) packi ng room The

P 3 0 ft lo ng wi t h screw—co nveyo r F bu-
cket , , .
, , ,

elevato r and packer F ( dri ven by a 2 0 h p motor) ; and coope r sh op ,

’
-
. .
-
.

Th e slag eye furnace of the Lone E lmwork s fi rst ere cted w

-
l
as bu il t of b ri ck

wi th water boxes and had two rows of tuye res ; i t has been replaced by an oval
-

water j acket furnace wi th a si ngle rowof tuyeres A plan and elevati o n of the
-
.

j ackets are shown i n Fi gs 1 06 and 1 07 and an elevati on of a pai r of furnace s .

,

wi th combusti on chamber i n Fi g 1 08 . .

1 D ewey lac ci t ,
. .

Hofman Lead
“
, , p recedi ng edi ti on,
1 2 8—1 30 .
1 24 ME TALLURG Y OF LE AD

o eni n s
p g i n the roof one of whi ch i s connected wi th a stack used temporarily
,

when the gases are to escape i nto the open while the other recei ves one li mb ,

of the connecti ng goose neck C -

, .

There are seven goose necks made of sh eet i ron gauge No 1 4 whi ch are to
-

,
-

,
.
,

cool th e gases and to coll ect the dus t no t deposi ted i n the towers A plan .
,

si de and end elevati o n of a set of goose necks are sh own i n Fi gs 1 09 1 1 1

-
— A -
. .

go o se ne-
ck i s 44 i n i n di a mete r and 2 5 ft hi
. gh and rests on a casi ng havi n g a t .
,

the fro nt cleani ng doors and apron plates for the removal of settl ed fum e -
.

EN D VIEW
w
Bo el " ELEVAT ION

Fl os 1 09 to — Plan si de and end elevati o ns of a set of oose necks.

1 1 1 g
- -
. .
,

Thi s has pi nki sh colo r I t i s collected dai l y to the amo unt of 3500 lb and
a . .

i s ei ther smelte d or so ld as an i nfe ri or pi gme nt mai nly to the rubbe r trade ,

.

Th e gases whi ch have been cooled and freed from du st and some fume pass
, ,

th rough the fan D Fi gs 1 04 and 1 0 5 i nto the deli very pi pe J and from thi s
, ,
.
,
-

, ,

through th ree branch es i nto th ree rows of hoppers K i n th e bag hou se E ach , ,
.

h0p p er has Fi g 1 03 2 0 b ags 2 0 i n i n di ameter and 30 ft long made of un

, .
, ,
. .
,

washed wool maki ng a total of 540 bags They are shaken twi ce in an 8 h r
,
.
-
.

shi ft . Th e pi gm ent whi ch collects i n the hoppers i s ei ther di scharged i nto the
screw—
’
co nveyo r F w hi ch de li ve rs to th e packe r F or i t i s carted i nto the pack
, , ,

i ng room and Shoveled i nto b arrels whi ch hold 500 lb pai nt

-
The advantage of . .

the conveyor i s that by worki ng i t free s th e pai nt from mechani cally i ncluded ,
 S M ELTI N G LEAD ORE S I N TH E ORE -
HE ARTH 1 25

gases and thus makes mechani cal packi ng possi ble ; furt her the work i s less ,

unsani ta ry than if done by hand A si milar arrangement i s di scusse d i n § 73 . .

I n b lowi ng i n a slag eye furnace thi s i s warmed w

-
i th wood the n fille d wi th -

, ,

coke and the blast turned on

,
When the coke has be come red hot on the sur .
-

face the fi rst ore charge i s gi ven Thi s i s fed i n small shovel lots at a ti me so
,
-
.
-

as no t to cool the red hot top ; feedi ng i s t he refo re a more or less co nti nuou s -

ope ra ti o n The compo nents of the charge and the manner of mak i ng up the
.

cha rge vary somewhat Gale na alo ne can be smelted wi th coke but fumace .
,

tro ub les are li kely to occur and ofl color pi gment m ay be formed In smel ti ng ,
-
.

si nte re d b lue fum e al one an almost pure basi c sulphate i s produced The .

usual three i mporta nt Pb and S beari ng compone nts are raw galena gray -

slag and burnt fume ; to th ese m

,
ay be added le ad beari ng m ate ri als su ch as -

drosses ski m mi ngs and scrapi ngs ofl color pai nt carbo nate ore etc C harges
, ,
-

, , .

smel ted i n 2 4 hr consi st of carbo nate ore 1 000 lb ; ashes fro m cooli ng towers
1
. .
, ,

1 500 ; bu rnt b lue fum es f rom ore h eart h 2 000 ; galena conce nt rate free f rom -

blende 6000 ; ofl colo r pi gment 1 000 ; cutti ngs

,
-
accreti o ns) from com bus ,

ti on chambe r 1 000 ; gray slag f rom ore hearth 1 000 ; metalli c i ron ( ti n cans
-

,
-

, ,

sweep i ngs from machi ne shop pud dle ci nder) 900 ; li mest one ( cru she d th rough ,

4 0-
me s h scree n) 4 ;
1 00 tota l ch a rge ih
, ; coke 6000 l b B l ai r
1
gi ve s ,
.
, .

the followi ng : Ashes 2 000 lh ; bu rnt blue fume 3000 ; gale na 6000 7000 ; ,
.
, ,
-

ofl co lo r pi gment —
1 000 1 500 ; cutti ngs 1 000 ; gr ay slag 2 000 ; i ro n 00
9 ;
-

, , , ,

li mesto ne 1 400 ; black slag (from slag eye fu rnace too ri ch i n Pb to go to the
,
-

dump ) 1 000 3000 lb

—
,
It w ill be noted that carb onate ore i s replaced by black
.

slag In ge neral the charges are made up wi th the vi ew of ob tai ni ng an abun

.
,

dance of fume of correct compo si ti on and a slag that wi ll run freely and carry ,

li ttl e Pb .

Th e fee di ng of the charge component s i s someti mes gi ven i nto the hands of -

the feeder who uses hi s own judgment as to requi rements B uskett recom ’
.

mends to wei gh out the charge components and mi x them wi th the excepti on , ,

of gal ena and coke A si ngle ch arge wou ld consi st of galena 500 lh ; gray slag
.
, .

and oth e r oxi de lead mate ri al 4 50 ; sili ca I o ; pu ddl e ci nder 1 30 ; li me sto ne , , , ,

1 0 ; total charge 1 1 00 lb ; and coke 1 3 5 lb ,

. .

In fee di ng the attendant first i ntrodu ces the coke and allows thi s to burn
,

freely ; scatters the galena over the top i n a thi n layer and sees that thi s bu rns
sa ti sfactori ly ; he the n covers i t wi th mi xture ; and fini shes wi th the bed of coke

of the ne x t charge .

Besi de the make up of the ch arge and the manne r of feedi ng there have to -

be consi dered the temperature of the top of the charge and of the co mbu sti o n
cha mber and wi th thi s the volume of ai r blown i n through the tuy e res and
,

drawn i n through the feed door i f a pi gme nt of the ri ght compo si ti on and color -

is to be obtai ned Besi de havi ng a hot top and a li qui d slag i t i s i mportant that
.
,

no i rregulari ti es or stoppages occur i n furnaci ng as oth erwi se th e pai nt obtai ne d ,

1 Buskett , lac . ci t .

1 Loc . cit .
1 26 ME TALLURG Y OF LE AD

will be of an i nferi or grade Thus when a furnace has been started the p roduct .
, ,

of th e first 4 or 5 hr i s cl assed as blue powder and that of the next 2 0 hr i s still .

, .

ofl color
-
The mai n p rodu cts of t he furnace are slag (b lack slag) subli med
.
,

lead and metalli c lead

,
Tab le 3 5 gi ves anal yses of black slag . .

T AB LE .

35
— AN ALYS E S
. or B LACK S LAG n on SLAG—
E YE FU R N ACE

Plant Si 02 FeO
I CaO
I2 11 0
l Pb Reference

Eagle Pi cher Lead Co

-
27 8 40 7 20 4
Busk ett, Mi n . E ng . World ,
Eagle Pi cher Lead Co
-
26 2 42 5 18 6
39 8
. .

1 9 , XX XVI ,
1 2 .

Eagle Pi cher Lead Cc

-
. .
3 2 2 3 6 0 1 2 5
W . W . Petraeus, p ri vate
Eagle Pi cher Lead Co 8
27 5 33 5 22 0 05
m
-

1 89 5
. .

co .
, .

St Loui s 8 81 R Co
H . Garli chs, p ri vat e 00 m .
,
. . . . . 25 0 33 5 I 7 5
1 9 1 4.

The sub li med lead i

essentially a basi c lea d sulpha te wi th s — 0 er cent
75 9 p .

PbS04 and 2 5 1 0 p er cent PhO ; th ere are u sually pre sent 2 5 p er cent ZnO ;
—
,
.
-
.

the content of ZnSO . ought not to exceed 1 per cent ; and that of C03 .

per ce nt Analyses are gi ven i n Table

.

TABLE 36 — AN A
.LYS E S or SUB La n LE AD Prcn m '

None None
None None
O O O O O O O O O O O O O O O O O 0 0 !

order to obtai n a basi c sulphate of co rre ct composi ti on i t i s es senti al

In
that the temperat ures be correct I t has been shown i n §40 that PbSO. heated .

°
i n a current of ai r i s i n part di sso ci ated at 705 C and that decompo si ti on .

i ncrease s wi th temperature he nce the i mpo rtance of havi ng a hi gh tempe rature ,

i n the combusti o n chambe r and of holdi ng the first cooli ng tower at about 800 C
-
°
.

Th e lead pro duced by the slag eye furnace i s hard and whi ti sh on account -

of the i mpu ri ti es taken up i n the smel ti ng .

The co st of a plant i n the M i ssi ssi ppi Valley treati ng 40 to ns ore p er day of ,

the character shown i n the drawi ngs i s esti mated by Buskett to be about 1
,

di st ri buted as shown i n Table 37 .

1 B usket t, lac . ci t .

1
Loc . ci t .
1 28 ME TALLURGY OF LE AD

73 F L B
.a r tl ett P ro
.c ess fo
.r th e T reat ment of Complex Zinc Lead Sul
1—
phi des T h e p r
.o c e ss,
fo rm erly ca rri e d out C anon C i ty Colo started in at ,
.
,

1 896 and befo re t hat date at Po rt land M e ( burnt i n

, ai ms to o xi di z e , .

and vo lati li ze the z i nc and lead of an ore th e re sul ti ng fume s to be saved ,

and the n re fined to a p i gme nt ; to co lle ct the p re ci ous m etals i n a C u Fe -

matte ; and to di spose of the gangue i n the form of a waste slag .

The Ora — The o re s commo nly tre ate d are an i nti m ate mi x tu re of sil ve r and
gold beari ng sulp hi des of z i nc lead and i ron i n varyi ng p ropo rti ons wi th
-

, , , ,

about 2 0 p er cent gangue They are di vi de d i nto two classes : tho se co nta i n
. .

i ng under 2 0 per cent Zn to be smelted rawi n the blast furnace and those .
-

co ntai ni ng over 2 0 per cent Zn to be worked i n th e si nteri ng or blowi ng up .

-

furnace .

S i nteri ng of Ore and Volati li zati on of Lead and Z i nc — The rawore cru shed .
,

fine and mi xed wi th bi tum i nous coal i s charged on a perfo rate d grate form i ng ,

the bottom of an arched chamb er red ho t from a p re vi ous charge ; u nde r and

FRO NT AND HALF S ECT ION S IDE ELEVAT ION

FI GS . 1 1 2 and 1 13 — Bartlett blow

. i ng up -
furnace for z i ncky ores .

over grate blasts are th en let on whi ch start the oxi dati on and rai se the tem
-

p erat ure a nd the r eby ,

change t h e loo se sulphi de ore i nto a mo re or less o xi di zed

and si nte re d m ass ; th e fume s pass off t hrough a flue and are coo led and co llected .

“
The fu rnace called a blo w i ng up furnace
,
i s shown i n Fi gs 1 1 2 and 1 1 3 -

,
. .

It co nsi sts of a perfo rated grate 6 ft long and 3 ft 6 i n wi de ( 4 and re st i ng , . . .

on the si de walls of the fu rnace and suppo rte d by cro ss b ars I t di vi des -
.

the arch ed cham ber i nto the ash p i t closed by the ash p i t doo r and t h e -

,
-

1 W hile the p rocess does no t stri ctly belong to a treati se on lead metall urgy ,
as it ext racts

the p reci ous etals rather by m m

at ti ng than by lead s elti ng, i t has enough p oi nts i n co on m mm
w m
i th the hearth treat ent of lead ores, i th the collecti on of sil ver beari ng u es by fil teri ng, w -
f m
and wi th other poi nts of lead smelti ng ,
to more than justi fy i t s i nserti on i n th i s book .

Bartlett , Colo S chool Mi nes —

S c Quart , 1 89 2 93 , 11 , No 1 1 ; M i n I nd 1 89 6, v ,
61 9 ;
mm
. . .
.
, ,

m
.

E nr Mi n J 1 889 . mm , 94 ; VI . 3 . 33 6 ; 1 89 6.
-
, 4 9 2 . 58 7. ,
1 72 .

Hofman ,
op . ci t , 1 89 3 , LVI , 44 7 .

Hawker , op . ci t
89 3 , LVI , 94
.
, 1 .

Long m ai d and Colli ns, op ci t , 89 6, LX I , 58 7, LXII , 2 4 3 ; Pri vate notes, 1 89 6

. . 1 .

Correspondent, Mi n E ng World , 1 908, XXIX , 1 6 7 (Wor s U S S elti ng

. . k . . m
 S MELTI N G LE AD ORE S I N TH E ORE H E ARTH -

hearth wi th i ts worki ng door ( 2 ) and flue ( 7) The roof i s supported by channe l

i ro ns and i ts bri ck si de walls ( late r replaced by water j ackets) rest on ho ll ow -

col um ns whi ch are pe rforated on the h earth si de to admi t ai r under pressure

on th e ch arge The ore mi x ture fills th e charge pocket s ( 8) and passes between
.
-

the columns ( 6) on to the he arth The blast enteri ng at . i s ad mi tte d under

,

th e charge through at the si de of i t through and on top of i t th rough

( )
6 t h us i nsur i ng the d e s i red degree of o xi d a ti on of the ch arge and espe ci ally
of th e fumes .

Th e ore conta i ni ng over 2 0 per cent Zn i s crush ed through a 2 me sh .

-

si eve m i x ed w
,
i th from 1 5 to 2 0 per cent slack coal and ch arged i nto the po cket s
.
, .

S uppo si ng a previ ous ch arge to h ave just been drawn the furnace to be red ,

h o t and th e charge pockets filled the furnace m

,
-
an w
,
i ll pu sh the charge down -

o n th e gr ate spread i t to a depth of about 6 i n th rough the worki ng door

, .

s ta rt the b last ; and fil l agai n the po ckets On arri vi ng on the grate the charge
.

wi ll consi st of ore and coke as the coal has gi ven up i ts volatile hydro carbons
,

whi le i t occupi ed the lower part of the po cket and the upper part of the i ncli ned
g ra te Th e c o ke i gn i te s and sta r t s ,
t h e ro as t sme l ti ng of the ch ar ge ; th e -

fla mes at fi rst blue from C0 so on be come whi te from the lead later
, ,
—

f rom the zi nc fumes ; the temperature ri ses the charge begi ns to cli nker , ,

a nd whe n the fume s have ceased to be evol ved about 30 m i n after chargi ng , .
,

th e blast i s shut ofl and the cli nker drawn out through the worki ng door wh en ,

t h e fu rnace i s ready for the ne xt charge N early all of the lead and mo st of
.

th e z i nc have been dri ven ofl and th e pre ci ous metals are co ntai ned i n the
,

matte whi ch wi th the slag forms the cli nker Any parts of the charge that
,
.

a re not agglome rated are returned to the furnace and wo rked wi th the ne x t

ch arge It takes from 2 0 to 40 m

. i n to trea t a charge the blast has a .
,

p res s u re of from 4 to 8 o z per sq i n . a fu r n a ce put.s th r

.ough
, about 6 to ns

i n 2 4 hr and one m . an attend s to two fu rnace s The compo si ti on of the .

cli nker of course

, must vary somewhat ; i t co ntai ns less than 1 per cent Pb
, . .

Analyses i n Table 39 show the other consti tuents :

TABLE — AN ALYS E S or CLI N RB R 1 11 011 B ARTLE TT PROCESS

39.

S mlli ng e o f S i ntered Ore and Volati li zati on of Zi nc

.
— The si nte red ore is
smel ted i n a low wate j keted blast furnace wi th exte rnal cru ci ble The
r ac
-
.

furnace i s worked wi th a hot top i n or der to volatili z e as much as po ssi ble of

the zi nc whi ch i s to be cooled and collected ; i ts acti o n i s oxi di zi ng rather than re
duci ng; copper ore i s added to assi st i n co llecti ng the preci ous metals i n th e
matte and to make a good separati on of i t from the slag The furnace 1 08 by .
,

9
1 30 ME TALLURG Y OF LE AD

3 6 i n the tuyeres i s shown i n Fi gs 1 1 4 and 1 1 5 In the figures (3) repres ents

. at , . .
,

t he fo unda ti o n walls well bound wi th i ro n ( 4 ) th e blast pi pe endi ng i n an ,

-

ai r ches t atta ch ed to the wate r j ackets th e b last pre heat ed by bei ng co ndu ct ed
- -

th rough the flues ( 5) the water i nlet and ( 6) the wat er outl et pi pes ( 7) th e
,
-

,
-

cha rge pockets t he charge sli di ng down the j ackets maki ng an angle of a bou t
-

, ,

and bei ng i n the ce nte r only abo ut 1 2 i n deep above t he level o f the tuy e res .
,

( )
8 t h e sh aft h e ld toge th e r by c or n e r i ro ns a n d ti e ro ds ( 9 ) th e flue co ll e cti ng t h e -

fumes from two furnaces and leadi ng them to the cooli ng chambers and bag roo m s ,

( 1 0 ) t h e tuy e re ope ni n gs l o ng i tu di n a l slot s 8, by 1 34 i n th e ad m i s si o n of a i r ,

.
,

bei ng regulated by a block push ed i n or drawn out by a small i ron rod attached
t o i t ( 1 1 ) the spout over whi ch the melted masses flow i nto an o verfl o w sla g
,

p o t ,
t h e bottom of th e fu r n a ce slanti ng 1 i n to the foot f rom back to f ro nt .
,

( )
1 2 t h e fou r stee l wa te r j ac ket s 4 0 i n h i g h
-

,
. .

END ELEVAT ION S IDE ELEVAT IO N

FI GS . 1 14 and 1 15 — Bartlet t
. blast furnace for z i nc ore
s .

The furnace ch arge i s made up by the addi ti on of sul phi de o res of zi nc ,

lead and coppe r and of some sili ci ous o res i n p ropo rt i o n to co ntai n 1 7 to 2 0
, ,

p er c e nt Z n 2 5 to 4
.
p e
,
r ce nt.Cu 3 to 1 0 p er ce nt Pb 1 5 to 2 0 p er ce nt
. S , .
, .
,

and 1 0 p er cent li me the re st bei ng S i 02 and Fe

. The amo u nt of coke u sed
,
.

ranges from 6 to 1 5 p er cent varyi ng wi th the pe rcentage of Zn that i s to be

.
,

dri ve n off as fume The furnace i s run i n su ch a w

. ay as to leave e nough S i n t h e

charge to bi nd all the Cu and the remai ni ng Zn and th u s mi ni mi ze th e loss of

Ag by volati li zati o n Th e blast p re ssu re i s 1 2 oz per sq i n

. The fu rnace puts . . .

through f rom 4 0 to 75 tons of charge i n 2 4 hr the amount depe ndi ng upo n .

,

the pe rcentage of Zn p resent Th us wi th 2 0 p er cent Zn 40 tons are smelte d .

, .
,

wi th 1 5 p er cent 50 tons wi th 1 2 p er cent 75 tons Three men attend the

.
,
. .
132 ME TALLURG Y OF LE AD

There i s mall gai n i n Au; the amount of Pb coll ected i n the fume show
a s s

an i ncrease over that accounted for by the dry assay ; th e lo ss i n Zn amounts

to 5 p er cent and i s accounted for by the assay of the slag

. .

The gase s from si nte ri ng and sm elti ng are drawn ofi by Stur tevant fans
placed back of a bri ck chamber havi ng a verti cal parti ti on extendi ng upward
from th e floor The obje ct of the chamber i s to mi x the gases from the si nteri ng
.

and smel ti ng furnaces and to equali z e thei r tempe ratu res Thi s i s necessary
, .
,

as th e fans sucki ng ofi hot fume s would crea te a b ack pressure on tho se taki ng

i n cold fumes In order to cool the gas mi xture th e fans suck i n cold ai r
. The .

coo le d and dil uted gases of appro xi m ately even tem perature and composi ti on
are fo rce d i nto an i ron ch amber Th ey enter at the bottom are deflected by .
,

the roof and drop a large amount of dust They then pass th rough a pai r of .

oblong sheet i ron cooli ng flues 8 by 3 ft and 1 400 ft long whi ch are suppo rted
-

, . .
,

i n the ai r on a lowroof shaped trestle so that the dust that settle s out about -

, ,

3 p er ce nt of the we
. i gh t of th e or e m a y be e asil y rem o ve d th roug h do o rs at t h e ,

side s and raked i nto wh eelbarrows or tru ck s Ge nerall y 2 5 sq ft of sheet i ron . . .

coo li ng surface are requi red for 1 sq ft of grate area of si nteri ng fu rna ce At . . .

the ends of the cooli ng flues the gases freed from du st pass i nto one of th e t w o , ,

bag houses use d al ternately where th e fumes are fil tered , .

A bag house si mi lar i n constructi on to th e one shown i n Fi g 1 03 contai ns

,
.
,

1 500 bags m ade of loo se ly woven cotton or wool The bags are 2 0 i n i n . .

di amete r and 2 1 ft long Cotton bags last from 1 8 to 2 4 months and woole n
. .
,

bags last from 6 to 1 0 years Wi th co tton the temperature of the bag room .

and wi th wool 1 2 0 C Ge nerally 2 00 sq ft of clot h

° °
should no t exceed 90 C .
, . . .

are requi red p er square foo t of grate area of si nter furnace and i f tw i ce cleaned ,

or shaken i n 2 4 hr 1 sq yd of woolen cloth wi ll collect 1 lb of fume p er

.
, . . .

day 1 sq yd of cotton cloth

, . . lb .

The rawfum e averages

=
1 2 PbS, 30PbSO4 ( + Pb803 1
) 4 2 p er cent .

1 4 ZnO + 4 oa 03 = 54 p er ce nt .

TC, 25 02, 1 5103 , et c .

4 p er ce nt .

Refini ng RawFu m obj ect of the refini ng

ei nto Re
fi d Zi l d Pi — Th m
m
ne nc ea g ent e -

process, whi ch i s anoxi di zi ng m u e roast i s to convert the lead and zi nc com -

pounds i nto Ph SO 4 and ZnO to eli mi nate finely di vi ded C As Cd and oth er , , , ,

i mpuri ti es and to compact the fume by grindi ng that i t m

,
ay be well adapted

for use as a pi gment The furna ce used for the pu rpose i s shown i n Fi gs
. .

1 1 6 and 1 17 .

In both figures,
( ) ep re se nts a p ai r of cast i ro n c
1y li n der s
r 1 0 ft lo ng a n d -

, .

1 2 i n i n di ameter
.
( )
2 a h e av y sp i r al scr ew w,
i th fou r lo ng i tud i na l fla t i ro n -

bars (not sh own) the screw conveyi ng the f ume from feed to di scharge and
,

comp ressi ng i t th e bars rai si ng i t and showeri ng i t through the ai r current

,

passi ng th rough the cyli nder ( 3) a d ri vi ng gear (4 ) th e feed hopper 5) the , ,

-

drum for coll e cti ng fine dust ( 6) t he screw co nveyer for refined pi gment ( 7) the , ,

1
Up on heati ng, PbSO : i s deco mpo ed i nto PbSO
s ., PbO, and
LE AD O RES I N TH E ORE H EARTH
-
1 34 M E TALL URG Y OF LE AD

dri vi ng pulley ( 8) the pulley of screw conveyer (9) the chi mney for prod ucts of
, ,

combus ti on ( 1 0) th e chi m , ney to carry ofl gases from the drum ( 1 2 ) a east i ron ,
-

disk wi th ci rcular ai r i nlet and di scharge spout ( 1 3) the fireplace and ( 1 4 ) - -

, ,

fines for the products of combusti on Fo ur cy li nders refine all th e fum e of the .

plant a cyli nder trea ting from1 2 00 to 1 500 lb of fume p er day The tempera
, . .

ture of the cyli nders i s kept at about 8 1 5 C Th e pi gme nt passi ng i n a bout °

.
,

20 m i n th rough a cyli nder i s di scha rged at ( 6) and then passed th ro ugh

.
,

bol ti ng clo th whi ch screens out any coarse parti cle s Four volumes of raw .

fume gi ve one volume of refined pi gment Thi s consi sts mai nly of 54 4 6 per —
.

cent Zuo 4 0 50 per ce nt P hso 4 a small amo unt of ZnSO 4 and an e xce
—
.
, . s s of ,

O the ulti mate analysi s gi ving Zn

,
Pb S Fegog etc , .
,

O per cent .

It i s bl ui sh whi te ( whi te lead bei ng yello w -

i sh whi te) de nse and sells at -

, ,

1 ct a pound les s than whi te lead

. .

Th e amount of dus t co llected i n the drum ( 5) i s sm all ( 1 lb per ton of ore) ; .

i t contai ns many rare elements .

The p lant of the Ameri can Zi nc Lea d Co of Canon C i ty Colo contai ned -
.
, ,
.
,

1 2 si nte ri ng fu rnaces ( si x of whi ch we re always runni ng) th ree blast furnaces ,

( on e be i n g h e l d i n r e se rve ) a n d t re a ted a bo ut 1 00 to n s of ore per ,

d a y T h e .

power requi red per ton of ore was about h p and the labo r 5 m a n
’

. .
,
.

The po wer w as di st ri buted as foll ows : Fi ve ex haust fans ( 6 1 75 h p ;

three underw i nd fans 40 ; two Baker blowers 30 ; one crusher and roller plant , , ,

n e l e tr i li g h t p l nt n re fin i ng p l nt 0 — tot l of h
5 ;
0 o e c c a 2 0 ; o e a 1 1 1 1 a a, 3 5 p
2 ,
.

The co st of treatment w as not made publi c but a trea tm ent charge for ,

g a le n a b l e n d-
e co n c e n tr a tes pub li sh ed by B art lett 1
gi v e s an appro xi m a te i dea .

H is ofi er was :
oz . silver at ct .
p er oz .
, less 5 per cent

1 8 p er cent . lead at 2 5 ct .
per uni t

p er cent . z i nc, nothi ng

Less trea t ent m .

Less frei ght

I 1 00 .

N et value

The plant w as shut down about as i t ceased to be profi tab le becau se

at that ti me electromagneti c co ncentr ati o n came i nto use, and payments had

to be made for the zi nc i n the ore i nstead of havi ng the benefit of the u sual
deducti ons for i ts presence .

Wi th the advent of th e eco nomi c deposi ti on of zi nc from sulphate solu ti on ,

the Bartlett proce ss was put i nto a posi ti o n to re cover the zi nc from the vo la
1
E ng M i n J 1 89 6 LX I 58 7
. . .
, , ,
.

1
Jackli ng M i n S c Press,
,
1 9 7
1 . . , cx rv, 6 1 7 .
 CH APTE R IX

Introducti on — Thepro e r i ed n i th b l t fu e i n of
74 . c s s ca r o n e a s rn ac s o e

redu cti o n The ai mof smelti ng a lead ore i s to set free the lead of the ore to
.
,

coll ect other metals su ch as Cu N i etc i n a matte and to fo rm of the gangue , ,

.
, ,

a slag lowenough i n v alues to be a waste p rodu ct Preci ou s metals whi ch e nter .

mai nly the lead but to som e ex tent also the matte are recovered by separate
, ,

pro ce sses .

All lead ores can be sm elted i n the blast furnace ; any ore contai ni ng over 4
per cent Slog must be so treated If the lead ore i s a sulphi de i t u sually i s
. .
,

fir st roasted or b last roasted ; if a carbonate or a mi xture of carbonate and sul

p hi de , the ca rbo n ate prev ai li ng i t i s sme l ted at o n ce A study of th e ch em i ca l , .

anal yses of arge nti ferou s ore g i ve n i n §4 9 and 50 wi ll sh ow that these ores ,

usually co ntai n much over 4 p er cent Si 02 Thi s explai ns the uni versal use . .

of the b last fu rnace i n smel ti ng th e ores of the Ro cky M ou ntai ns and P aci fi c
.

di vi si o ns of thi s cou ntry I n Table 4 1 are li sted the silver lead smelti ng works
.
-

of t he Uni ted S tates Canada and M exi co i n operati on i n , ,

Wi th the lowSi O, non argenti ferous lead ores of th e Mi ssi ssi ppi Valley
- -

whi ch have not been sufi ci ently enri ched by mechani cal conce ntrati o n to fu rni sh
a produ ct su i t ed to th e reverberato ry f urnace or the ore hearth the b last furnace -

i s theo nl y efi ci ent smelti ng apparatu s .

The treatme nt of lead o res i n the blast furnace u sed to be and someti m es ,

sti ll i s di scu ssed u nder th e h ead s of P re ci pi t ati o n and Roasti ng and Redu cti on
,

for sul phi de ores and of General Redu cti on for carbo nate o res Thi s classifi
, .

cati o n whi ch had i ts ori gi n on the E u rope an conti nent w

,
as ju stifi ed by the ,

practi ce of i mportant smelti ng centers i n whi ch large m i nes furni shed smelteri es
wi th u ni form ores whi ch were smelted i n one of the three ways Th us e g .
,
. .
,

i n the H arz M ountai ns P russi a galena co ncentrates used to be smelte d w ,

i th ,

the addi ti on of sufi ci ent i ro n to carry on the so called preci pi tati on pro cess -
.

In other parts of th e E urope an conti nent sili ci ou s sulphi de ores we re ordi naril y
subje cte d to slag roasti ng i n a hand reverberatory furnace and the p rodu ct
-

smelte d i n the b last fur nace ; there prevaile d the roasti ng and red ucti o n p ro cess .

The treatment of o xi de ores i n E u rope i s confined to i ntermedi ary produ ct s of

lead refineri es and th e se are rarely smelted by th emselves ; h ence the general
,

reducti on process was carri ed out only i n excepti onal cases .

In the ce nt rally si tuated cu stom smel teri es of the Uni ted S tates whi ch ob ,

tai n thei r ores from di fferent parts of the country i n varyi ng quanti ti es the ,

1 D wi ght , E ng . Mi n . J .
,
1 9 1 6, 011 , 6 71 .

1
E ng . Mi n . J .
, 1 9 1 8, CV, 63 .
 S MELTI N G LE AD ORE S I N TH E BLA S T F URN A CE
’

TAB LE — AME RI CAN SI LVE R LE AD SR E LTING W onx s

41 1 91 7
-
.
,

Co mpany

Ameri a n Smlti ng and R fini ng Co

c e e D enver , Colo
Am i can Sm
er el ti ng nd R fini ng Co a e Pueblo, Colo
Amri can Sm
e elti ng and Refini ng Co D urango , Colo
Am ri can Sm
e elti ng and R fini ng Co e Leadville, Colo
Ameri an Sm el ti ng and Refini ng Co
c M urray, Utah
Am i can Sm
er elti ng and R fini ng Co e East Helena, Mont
Am eri a n Smelti ng nd R fini ng Co
c a e O mah aN eb ( b)
, .

Amri an Sm
e el ti ng and R fini ng Co
c e Perth A boy, N J m . .

C n Kansas Ci ty Sm and R f Co
o . . e . E l Paso, Tex . .

B unker Hi ll Sulli van Mi n . and Concentrat Kellogg, I da

i ng Co .

Selby S mlti ng and Lead C e o

O hi oCol ad Smlti ng C or o e o

U ni t d States Sml ti ng C
e e o

N rthp ort Smlti ng and R fini ng Co

o e e

P nn ylvani a Smlti ng Co
e s e . .

I nternati onal Smelti ng Co

T otals, Uni ted Sta tes .

Am i can Smelting and Refining Co

er M onterey
eri ca n Sm
.

Am elti ng and Refini ng C o Aguascali entes

a i ca n Sm
.

Am elti ng and Refini ng Co . Chi h uahua

Am eri can Sm elt rs Securi t i e s Coe Velardena
C m o
p a n i a M e ta llu rgi ca M xi cana e San Lui s Potosi ( c)
C m o
p a n i a M e ta ll urgi ca de T o rreo n Torreon
Co mp a n i a M i n er a d e P en ol e
s Map i mi

Co nsolidated Mi ni ng and S melti ng Co Trail , B C .

h ( b) S m hi fly medi ary products p

'

( ) T ons
2 of c arge. el t s c e refinery i nt er .
( c) N ot bei ng o erat ed . but
pla nt is exp ect ed to st art i n the ne ar fut u re .

re gulari ty of treatment prevalent i n E urope cannot be followed All the ores .

re cei ved go to make up the blast fu rnace charges ; they are vari ously apporti oned

i n order to form sui table m i xt ure s as regards lead co nte nts and the amou nts and -

ki nds of slag and matte formi ng co nsti tue nts The sulphi de ores may or m -
ay .

no t be roasted or blast roasted ; o xi de ores wi ll be smel ted rawwi thout any p re

li m i nary tre atment unless they are too fine for thi s p urpose and are better sui te d ,

to make up blast roasti ng charges I n order to meet these condi ti ons smelti ng .
,

i n the blast fu rnace wi ll be treated b roadly as a f usi on i n whi ch reducti o n and

sco rifi ca ti on are the l eadi ng chemi cal pro cesse s while preci pi ta ti on and sul ,

p h u ri za ti on are of se co nda ry i mpo r ta n ce .

ci l—
In vi ew of the fact th at the p ri n pal meta be ari ng mi ne rals whi ch enter
t h e b last furnace are sulphi des and that they u su ally h ave to be roasted or ,

blast roasted befo re they are u sed to m ake up the charge s i t i s necessary to ,

co nsi der first these two preparatory ope rati ons .

1 38 ME TALLURGY OF LE AD

75 O xi di zi
. ng Roast of Metalli c S ulphid es i n Po der For T he ge ne ral w m
—

reacti ons tha t take place when a metalli c sul phi de i n powder form is hea ted w i th
access of ai r have bee n trea ted elsewh e re
1
H ere the behavi or of the sev eral .

sul phi des li kely to be met melti ng will be studi ed i n lead s .

1 Lead S ul phide PbS

.
—
The behavi or of PbS has been studi ed i n § 39 4 1 .
-
.
,

2 I ron Monosul phide FeS

.
— The change s FeS unde rgoes m ay be exp ressed ,
.

accordi ng to P tt er by
l n 1
FeO + O = F 304 and
a : 3 e

2 Fe3 04 + S03 = 3Fe0 3 + SOg and

and
°
Pure FeS i gni tes i n ai r at from 32 5 mm or 1 00 me sh) to 4 72 C .
-
°
.

mm or 50 mesh) and does not decrepi tate upon heati ng

.
-
3
H eati ng .

FeSO. i n a cu rrent of ai r cau ses i t to be readi ly decompo sed at 4 80 C for m

4 °
i ng .

yellow brown Fe303 2 S03 and thi s basi c ferri c salt i s completely changed at
-
.
,

to 0 b i c sal t F8 25309 of rece nt i nvesti gati o n i n

°
5 6 0 i n re d F 02 3 an d S O 3 Th e a s .

the labo ra to ry di ffers from t he Fe, SO . of Plattner ; i n the furnace bo th are

li kely to be forme d .

I D i u l h i d F S — If he te d w i th e l u i o of i to C ls
S
°
3 ro.n s p e e a a xc s n a r 2 00 , .
,

begi ns to di stil off ; at 700 the di sso ci ati on i nto FeS and S i s complete “ H eati ng
°
.

—
wi th access of ai r to 2 50 2 90 C ca uses oxi dati on take place accordi ng to
" ° °
.

At temperatures lyi ng between 2 90 and 500 the reao °

FeSg+ 3Oz FeSO4 + SOg .

=
ti on 4 FeSg+ 1 1 Oz 2 Fea + SSO, prevails Pyri te from E lba gi ves off SO; at "
.

i
°
45 0 C
°
a n d g l ow
. s a t t h at from R i o T n to '
beg i n s to ro as t at 2 60 2 75 C -
°
.

Al though FeS, contai ns more S than FeS i t roasts wi th grea ter rapi di ty ,

because i n the process some S i s di sti ll ed off whi ch burns freely and leaves porous
the remai ni ng F05 whi ch nowofi ers many poi nts of attack for oxi dati o n ; th ere ,

i s al so set free a larger amount of SO3 whi ch has a strongly oxi di zi ng efl ect , .

4 C u p
. rou s S u lp h id e C rux — O x i d a ti o n m a y be e xp re ss ed ac c o rd i n g to ,
”
Plattner by CuO +
Sn i CuSO L Laborato ry e xpe ri me nt s by Aubell show that prepared CU gS 11

begi ns to roast at 2 00 C wi th the reacti on 2 CugS+ 503 = 2 Cu0+ 2 CuSO 4 whi ch °

.
,
°
conti nues up to 330 ; th at above 330 the reacti on CugS + Og 2 CuO + SO z begi ns ;
°
and that up to 550 more than half of the sulphi d e S i s converted i nto sul -

phate S H e finds also that

-
. set free by the di ssod ati on of CuSO 4 11
acts ,

1 Hofm an H C General Metallurgy McGrawHi ll Book Co NewYork 1 9 1 8 4 03 -

. .
, . .
, , , , ,

1
Plat tner, C F . .
,
Di e Metall urgi schen Rostp roccsse, Engelhardt , Frei berg, 1 856 , 1 33 .

1
Fri edri ch , M etall urgi e, 1 909 ,
VI , 1 69 .

1 Hofman -
W anjukow Tr A I M . E . 1 9 1 2 , X LIII , 54 8 .

mm
.
,
. .
,

Kothny, Oester J ahrb , . . 1 9 1 0, , 1 1 2; M etallurgi e ,

191 1 ,
VIII , 389 .

1 Geode] ,
I .
fil l Gasbel euchtung, 1 0
9 5, X LVI II , 400 .

Fri edri ch, S tahl u E i scn, . 191 1 , XXX I , 2 04 0 .

7
Ko thny, loc . ci t .

1 Fri edri ch , loc . ci t .

1
Cha lon, Rev U n M i n . . .
,
1 90 2 , LVII , 201 .

1°
Loc . ci t .

11 Ocs ter J ahrb , . . 1 9 1 0 , LVI I I , 1 3 1 .

803
°
8 03 ; 2 CuO SO a at 736 C 2 CuO
°
11
2 CuSO 4 at 6 70 C . 2 CuO . SO a . . .

Hofman Wanjukow Tr -

, . A I . M . E .
, 1 9 1 2 , X LIII , 54 7 .
1 40 ME TALLURG Y OF LE AD

Manganese S ul phide M118

8 . by roast ,
— The mi neral albandi te i s co nverted

i ng i nto MnSO . and Mn. o. ; the MuSO. i s readily converted at 790 C into 1 °
.

dark red to black Mn304 whi le SO; SO; and O are set free The i gni ti on , , , .

temperature was found by Fri edri ch to li e at 355 C whe n

1
mm or 1 00 °
.
,
.

me sh i n si ze and at wh en mm or 50 mesh The m

,
i neral does not .
-
.

de crepi tate .

S il S ul hid A S — I f rge t i te i gi ve o i di i g ro t i t i
'

9 .ver p e g, a n s n an x ,z n as s .
,

co nve rte d i nto finely di vi ded Ag and SO, as seen by

°
The compou nd Aggo cannot fo rm as i t i s di sso ci ate d at 383 C i nto Ag, 1
, .

and O The i gni ti on temperature of argenti te

. mm or 1 00 mesh i n si ze ,
.
-

was found by Fri edri ch to be 605 C and 875 if of

1
mm or 50 mesh si ze °
.
,
°
.
-
.

The roasti ng of Ages i s attended by lo ss i n Ag If present i n sm all quan ti ti es .

i n other metalli c sulphi des the SO; set free i n th ei r decomposi ti on has a ten ,

dency to exert a sulphati z i ng effe ct : and Ag, S +

SO = A SO + S O Th e de ompo i t i o n of A SO w h ethe a u e d by h e a t
4 a g g 4 4 g c s g , 4 r. c s

or the presence of oxi des such as Fe304 or Cu30 i s attended by a co nsi der , ,

ab le lo ss i n Ag The reacti on m ay be e xp ressed by An o4 at 9 2 5 C

°
Agg+
'

. .

SO, O ; AggS04 + 4 FeaO 4

Ii
2 Ag + 6Fe203 + SOz ; An O4 + 2 Cu¢O 2 Ag + 4 CuO
+ 802 In ro asted ore the silver wi ll be found to be present
. as undecomp osed
Agzs, as Ag2804 , and as Ag .

76 R oasti.ng, Gene ral The ai g roast i s to oxi di z e metalli c .

1 -
mof an oxi di zi n

sul phi de and to dri ve off as much 8 as po ssi ble i n the form of 803 .

The H all proce ss whi ch ai ms to roast sulphi de ore i n su ch a w

m
ay as to con
7
,

vert the etal i nto oxi de to exp el the S as vapor and to recover the vapo r i n the , ,

form of flowe r of sulphur has not yet been tri ed i n connecti on wi th le ad ores ,
.

A questi on to be de ci ded wi th each ore i s whether i t i s ne cessary to ro as t i t ,

or i t i s better to sm el t i t raw Th e character and am ount of sulphi de the .

,

ri chness of the ore and th e cost of the operati on wi ll be the deci di ng facto rs
,
.

As a rule any ore contai ni ng 8 per cent S or over i s best roasted before i t is
,
.

smel t ed The ri chness of th e ore i n Ag and i ts coarseness m

. ay m odi fy t hi s gen

eral rule As ro asti ng i s always connected wi th loss i n m etal i t may be more

.
,

profi table to smelt rawan ore ri ch i n Ag even if i t contai ns over 8 p er cent S .

,

than to first gi ve i t an oxi di zi ng roast A lead ore w i th 1 00 oz Ag p er ton . .

i s rarely roasted ; some metallu rgi sts have drawn the li ne at 50 oz per ton
‘
1
.
,

whi ch however seems to be rather low .

Gold mill conce nt rate s w i th 8 p er cent S are practi cally al ways roas ted .
,

as the co m mo n sulphi de mi neral pyri te Pcsg i s readi ly o xi diz ed and the , , ,

Fe , 03 freed from S form s a valuable flux ; fu rther bei ng finely di vi ded the , ,

1 Hofman Wanjukow Tr -

,
. A I M E . . . .
,
1 9 1 2 , X LI I I , 5 2 3 .

1
Loc . ci t .

1 Stahl , M etall urgi e ,

1 9 0 7, Iv, 690 .

1
Loc . ci t .

1 Hof man Wanjuk aw loc -

,
. ci t .

1
These general consi derati ons hold good fo r blast roas ti ng, § 84 .

7
Hofman Mi n I nd 1 9 1 4 m m 4 77 ,
. .
, , ,
.

1 Newhouse E ng M i n J 1 89 1 LI 2 60 ,
. . .
, , , .
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN A CE

o e t te s are li kely to cause trouble i n the furnace unl ess they are some
c nc n ra

wh at agglomerate d .

Pu re argenti ferous galena ores do not often come to smelteri es i n su ch quan

ti ti es as to make a separate trea tment ne cessary ; stri ki ng excepti o ns are found
i n so me works i n Idah o and Montana Ordi nari ly pure gale na concentrate .
,

i s added to an ore bed i n such quanti tv as to make up for the commo n

-

de fi ci ency i n lead of the blast furnace charge Im pure gal ena ore i s usually .

mi xed wi th sulphi de ore s free from lead before roasti ng Thi s i s done for .

tw o reaso ns to reduce the S content of the roasti ng charge and to fur ni sh

,
-

th e re qui red lead for the blast fu rnace charge If a roasti ng charge co ntai ns .

o ver 2 0 p er cent S i t i s li kely to be come sti ck y at the begi nni ng of th e

.
,

roast and thi s mu st be avoi ded i f the S i s to be e li m i nate d sati sfactori ly

, .

P yri te ores i n the blast furnace consume mu ch S as seen by Fe5 2 + Fe

2 FeS th ey i ncrease the co st of sme l ti ng redu ce th e capaci ty of the fu rnace for
, ,

o re, and form mu ch m atte wh i ch on account of i ts co nte nt of Pb and Ag , ,

di m i ni sh es the di re ct yi eld of the se two metals i n the lead bul li o n The matte .

h as to be roaste d before i t i s resme lted to recover th ese values Th e Fe ori gi nally .

added to th e ore charge become s agai n avai lab le so that th e actu al consumpti o n
-

of Fe i n smel ti ng raw su lp hi de o res i s not so grea t as i s ge nerall y assumed .

W h ether a pyri ti c ore shall be roasted or not i s deci ded by the p recentage of S i t
co ntai ns over that whi ch i s requ i red to cover as Cugs the amou nt of Cu prese nt .

H owever a large matte fall has to be avo ided i n smel ti ng as the amount of
,
-

Ag e nteri ng the slag i ncrea ses wi th the perce ntage of matte forme d Thi s .

ha d eflect begi ns to be seen wi th 1 0 p er cent of matte i n th e charge ; every .

fu rnace man tri es to keep hi s matte fall under 5 per cent -

.

B le nde has a very delete ri ou s efi ect upon b last fu rnace work by formi ng a
mushy matte whi ch i nterferes wi th the work at the tuyere level and by i n
,
-

cru sti ng the si des of th e shaft wi th fume s of z i nc more or less o xi di z e d resu l ti ng , ,

from the decomposi ti on of ZnS by Fe or Cu and t he sub seque nt volati li z ati on ,

o f t h e Zn If prese nt to any ex tent the ore will have to be roasted so that

.
,

t h e o xi de m ay be take n up by the slag and th u s carri ed out of the fu rnace .

I n a ge ne ral w ay i t m ay be sai d that th e h i ghe r the percentage of Pb in the

ch arge th e grea ter i s the amount of ZnS tha t i s perm i ssi b le

,
For i nstance .
,

i f i n th e practi cal ab sence of F6 52 the percentage of Pb i s tw ,

i ce that of Zn the ,

o re m ay be smel ted raw ; if Pb an d Zn are p res e n t i n equ al amo u nts or if th e r e ,

i s le ss Pb than Zn the ore must be roaste d before smel ting

,
Attenti o n has .

b een called i n to the slowness wi th whi ch ZnS gi ves off i ts S .

77 R oas
.ti ng F u rna c e s , G en eraL— T h e ro as ti ng of lea d o r e s ca n be car ri ed
on i n heap s stalls ki lns and reverberatory furnaces
, , ,
So call ed mi xed .
-

sulph i de o res consi sti ng m ai nly of galena p yri te

,
chalcopyri te and b lende , , , ,

are so met i m es roaste d i n h eap s and stalls the sulph urou s gase s bei ng allowed ,

t o go to Waste ; or th ey are roasted i n k i lns whe n the SO, i s to be co nve rted ,

i nto s O 4 As thi s m . anne r of roasti ng i s com parati vely rare wi th lead

o res ,
but commo n wi th copper ore s and as the apparatus i s practi cally ,

th e same th e methods are om i tted here

,
They have bee n fully di scussed .
142 ME TALLURGY ’
OF LE AD

elsewhere One i nstance the heap roasti ng of concentrator sli mes at Port
.
1
,
-

P i ri e N S W deserves me nti on as i t i s a si mple and i nexpensi ve meth od of

,
2
. . .
, ,

handli ng a ve ry trouble some materi al if i t cannot be added to th e charges of ,

the b last ro asting apparatus .

B efore the advent of b last roasti ng the reverberatory furnace w as p re

é mi nently the apparatu s i n use for roasti ng lead ore s H and rabbled furnaces .
-

of di fl erent forms were i n operati on i n every smel tery for the roasting of ore
and m atte The great su ccess of me chani cal furnaces i n the rough roasti ng
.
-

of sulphi de c0pp er ore s prompted lead works to foll ow the example of copp er
metallurgi sts wi th the resul t that the mechani cal roasters of Ropp Pearce , ,

Brown O H ara Keller Wethey and Brii ck ner were erected and adapte d to
’
, , , , ,

the treatment of lead ore s Though they redu ced the co st of roasti ng i n com .

pari son wi th the work i n the hand reverberatory furnace th ei r work on th e -

whole was not sati sfactory for several reasons .

In order to redu ce th e S co ntent of a lea d beari ng ore to a required degree - -

i t i s if not nece ssary at least desi rable to be able to accelerate and retard the
, ,

travel of the ore from the feed to the di scharge and toward th e end of the ,

roast when the temperature i s bro ught to th e hi ghe st pe rmi ssi ble poi nt to
, ,

rake and turn over the charge much more frequently than at the begi nni ng ,

i f a sati sfactory eli mi nati on of S i s to be effe cted In a me chani cal furnace .

wi th stati onary hearth the raki ng and turni ng over of ore i s uni form as i t -

depends upon the speed of the rakes If these travel too slowly the ore wi ll .
,

be i nsufi ci ently worked near the di sch arge ; if too qui ckly th e ore near the
feed w i ll be turned under while the S on the surface i s sti ll burni ng wi th the ,

resul t that th e ore wi ll cake and form lumps As thi s mu st be avoi ded the m e .
,

chani cal f urnace has to be run slowly and the ore no t bei ng sufi ci ently roasted ,

toward the end of i ts path wi ll retai n a comparati vely large amount of S Th e , .

re lati vely sm all quanti ty of ore th e mechani cal furnace puts through when i t

has to reduce the S content to say 3 per cent very often does not warrant th e -
.
,

expense of erecti ng a f urnace and of keepi ng i t i n repai r 1

Another di fi cult y ,
.

i s that of the ore caki ng on the bed of loose materi al wi th whi ch the b ri ck hearth
i s cove red and ob structi ng the passage of the sti rre rs
, Thi s has been overcome .

i n part by plowi ng up a crust as soo n as i t fo rms ; others have found i t pref

erable to all ow a crus t to fo rm and wear off the b lades of the rabb le s an d ,

to sh ut down the fu rnace when the blades become too short remove th e ,

crusts and supply newb lades to the arm s

,
I t has also been found that t h e .

blades last a much shorter ti me i n roasti ng lead ores than pyri ti c ores Thi s .

must be caused by a chemi cal effect of the ore as there i s no reaso n why th e ,

mechani cal wear should be greater w i th lead beari ng than wi th copper bearin g - -

1 Hofman H ,
. O .
, M etallurgy of Copp er , M cGra wH ill
-
Book Co .
, N ew York , 1 9 1 8,
—
7 1 1 14 .

1 Horwood ,
Tr Ausl r I nst . . . Mi n . E ng , . 1 903 , IX , 1
1 06 .

Delp rat , o p
. ci t .
,
1 9 7,
0 X II , 1 M i n J 1 90 7 LXXXVII 3 1 7 5 1 7
5 ; E ng . . .
, , , , .

“
Hof man H ,
. C .
,
General M etallurgy McGrawHill Book Co NewYork
”
,
-
.
, ,
191 8, 63 5 .

1 Iles, E ng . Mi n J . .
,
1 900 , LXX , 1 85 .
144 ME TALLURGY OF LE AD

thi ckness of bed vari es from 3 to 6 i n ; th e

. rabbli ng is repeated every 34 to
1 56 hr .

The ti me requi red to roa t an

depends upon th e readi ness wi th whi ch i t s ore

oxi di ze s and fuses Ores i n whi ch galena prevai ls requi re a slow roast and a
.

lowtempe rature th roughout as even wi th the m ost careful work i t i s di fi cult ,

to prevent roasted ore from retai ni ng undecomposed PbS Pyri ti c ores can .

be roasted qui ck ly ; the re i s no danger of half ro asted ore becomi ng sti cky -

and adh e ri ng to th e h ea rth of th e furnace Ores ri ch i n blende requi re a . .

consi de rab le ti me and a com parati vely hi gh temperature i f the ZnS i s to

be completely conve rted i nto ZnO and ZnSO . and the latter to be fully ,

decompo sed .

The tempe rature at whi ch the roasted ore i s to be wi thdraw n from the
fu rnace must be regulated by the character of the sulphates formed and by
the fusi b i li ty of th e charge The charge can be ta ken out of th e furnace as a .

pulve rulent a si ntere d or a fused mass As regards subsequent smelti ng i t i s

, ,
.
,

best to slag the ore as by obtai ni ng the roasted ore i n IM p fo rm the di sadvan
,

tages of treati ng fine ores i n th e blast furnace are ove rcome ; but o ther consi de ra
ti ons prevent thi s The leadi ng one s are lo ss i n Pb and Ag and the i ncrease
.
,

i n co st N ew house gi ves as a re sult of a seri es of expe ri ments i n roasti ng ores

.
1

contai ni ng f rom 1 2 to 1 8 per ce nt Pb a loss of from 1 5 to 1 8 er cent Pb and of

p .
, .

2 p er cent Ag wi th fu si on of roast and one of from 2 to 5 e ce nt Pb w i th n o

.
p r , .

loss i n Ag wi thout fusi on .

I n Mi ssouri wi th pure galena concentrate the loss i n Pb used to be 1 0

w
per cent wi th fusi on By agglomerati ng or si nte ri ng the roast i nstead of
. .

fusi ng the loss i n metal wi ll be only sli gh tly hi gh er than hen i t rem ai ns
,

pulve rulent The S wi ll not be so eflectually removed as when the ore

.

i s slagged but mo re so than whe n i t rem ai ns a po wder

, For i nstance slag .
,

roaste d ore contai ns from 1 to 3 per cent S while roasted pul ve rulent ore .
,

co ntai ns from 3 to 7 e r ce n t S T h lo i n ea n th w h o le w i t h t h e
p e ss c r ses o e . .

lead content of the ch arge

-
I t used to be sai d that an ore wi th 1 0 per cent . .

Pb or less could be safely slagged ; wi th from 1 0 to 2 0 p er cen t Pb o nly .

agglome rated ; w i th over 2 0 per cent Pb the temperatu re h ad to be kept so .

low th at th e roaste d p ro du ct rem ai ne d pul ve rulent or only sli gh tly adhe ren t ,

when wi thdrawn f rom the f urnace Such ore was drawn from the furnace i nto .

a slag pot and pounded hot w

-
i th i ron di sks so as to m ake the parti cles adhere
to one another 1
.

Th ese sta tements refer to mix ed su lphi des formerly trea ted i n Western
smel te ri e s wh i ch as a ru le ran lowi n Pb and hi gh i n Ag
, They are not appli ca .

ble to pure galena conce ntrates practi cally f ree from Ag ( as i n th e Mi ssi ssi pp i
Vall ey) or lowi n Ag ( as i n mo st E uropean sil ver lead wo rk s) becau se i n bo th -

case s the ores u sed to be slagged to a greate r or less degree The charges .
,

ru nn i ng f rom 50 to 60 per cent Pb and bei ng nearly free from i mpur i ti es .

,

requi re when roasted o nly a very sli gh t i ncrease i n temperature to be slagge d

, , ,

1
E ng . M i n L 1 89 1
.
, ,
LI , 2 60 .

1
Iles, Eng M i n J
. . .
, 1 900, LXX , 1 84 .
 S M ELTI N G LE AD ORE S I N TH E BLAS T F URN ACE
’

care bei ng tak en to keep the temperature as lowas po ssi ble Therefore the .

lo ss i n Pb and Ag i s not great al though the perce ntage of Pb i s hi gh .

L n b d R v b t r H an d ro a s tin F u n a — T hi ld t n dby
79 o g e e er e r a o y g r c e s o s a
- -
.

h as al so seen i ts best day s ; i t still retai ns however i ts usefulness i n cases i n , ,

whi ch blas t roasti ng has not been able to make headway The furnace has a .

si ngle roasti ng h earth from 4 0 to 80 but u su ally 60 ft lo ng and from 1 4 to 1 7 ,

.

but u sually 1 6 ft wi de a fireplace at one end and a flue at the other and work .
, ,

i ng doors on ei th er si de through whi ch the ore fed near the flue end i s slowly ,
-

worke d down to the bri dge end and there di scharged -

,
.

Fur naces w i th two superposed h earths have been u se d i n order to save

1

floor space and to redu ce the fuel consumpti on

-
The di sadvantages such as .
,

mo re soli d co nstructi o n repai r on lower hearth requi ri ng removal of upper ,

h ea rth difi culty of m ,

ovi ng ore on upper hearth whi le standi ng on a shak y
platfo rm wi th resulti ng carelessness of work and buildi ng up of cru sts whi ch
h ave to be b urnt out or cut out etc have made the doub le hearth th e excep ,
.
,

ti o n Lo ss of heat th rough the roof of the si ngle hearth i s easi ly corre cted by
.

coveri ng wi th sand ; i n the doub le bed f urnace th e h ea t passi ng off throug h -

th e roof of the lower hearth h eats the floor of the upper .

Th ree ki nds of si ngle hearth fur naces have been e re cted i n lead smelter i e s -

A furnace havi ng a level h earth a slaggi ng hearth ( fu se box) and a si nteri ng ,

-

h ea rth Though the level h ea rth i s sti ll i n use and the fu se box w
. as rep laced ,
-

i n Co lorado abo ut 1 898 by th e si nteri ng hearth and th e last has m ade w

1
ay i n ,

mo st plants to blast roasti ng apparatu s the threetypes have not outli ved thei r ,

u sefulness and deserve to be di scussed ,

.

80 ReverberatoryH and roasti ng Furnacew

. i th Level H earth — Thi s furnace -

sh o wn i n Fi g s 1 1 8 1 2 3 w as i n ope rati o n at the work s of the M o ntana Sm el ti ng

—
,
.

Co Great Falls M ont

.
,
The hear th 40 by 1 4 ft i s sho rter than i s u sually
,
.
,
.
,

the case the general leng th bei ng 60 ft The reason for the shortne ss i s that
,
.

th e ch arge i s to be wi thdrawn near the firebri dge i n a pulverulent state thro ugh
two di scharge openi ng s i n the bottom ; the temperature bei ng kept lowat the
-

firebri dge the le ngth of 4 0 ft i s suffi ci ent to utili z e all the hea t generated on the
,
.

g ra te A tte nti.o n m a y be c a ll e d to th e v a u l te d a rch e s w h i ch s upp o rt th e h e arth ;

th e ab sence of ofi sets in the hearth whi ch h as a ge ntle ri se from b ri dge to ,

flue wh i le wi th 2 i n offsets every 1 0 ft there would be four level h earths

,
-
. .

sep arated f rom one anoth er by 2 i n st ep s ; th e slope f rom ce nter li ne to si de s ; -

.
-

th e di scharge openi ngs for roasted ore ; the damper i n the flue ; the di stance of
-

—
54 i n betwe e n .wo rk i ng d oo r s w hi ch i s le ss th a n u su a l (7 9
2 6 t h e w i dt h of ,

fireplace 2 1 ln Fi g 1 2 3 whi ch provi ng i nsufi ci ent for the lowgrade coal

,
.
,
.
, ,
-

used w as i ncreased to 36 i n Fi g 1 1 8 ; to the narrowi ng of th e firebri dge from

,
. .

2 7 in Fi g 1 2 3 to .
,
i n Fi g 1 1 8 to fu rni sh th e room ne cessary for the en
.
,
.
,
.
,

1
M echerni ch , Berg H atten . mZ . 1 875, XXXIV, 1 2 9 ( Jaeger) ; op . ci t
.
, 1 886, X LV, 4 34 ; E ng
.

Mi n . J .
,
1 8 7 7, XX I II , 1 36 ( H up p ertz) .

Pi i bra '

m Oester ,
. J ahrb , 1 890, XXXVII I , 1 1
.
( Zdrahal) .

Iles, E ng . Mi n . J .
, 1 900 , LXX , 1 84 .
146 ME TALLURGY OF LE AD
14 8 ME TALLURG Y OF LE AD

li ned wi th
t i ron frame carri es a steeply i ncli ned fixed steel plate 34 i n
a cas -

, , .

thi ck and a swi ngi ng plate suspended by trunni ons i n such a way that wh en
,

th e h opper i s empty th e mov able p late clo ses the sp ace betwee n the cas t
,

i ro n li ni ng and th e fix ed p late and wh en i t i s bei ng filled the plate recedes and , ,

all ows th e charge to d rop on to th e h earth .

Temperature measureme nts i n such a furnace 58 ft long roasti ng leady , .

,

matte have been made by C levenge r They a re shown i n Fi g 1 2 4 Th e

,
1
. . .

temperatures on si de A we re taken after movi ng the charge forward and

duri ng the hi ghe st heat ; those on si de B at the lowhea t prevai li ng when the
charge i s to be dr aw n .

A
e
d
i

F1 0 . 1 24.
— Te mp erat ure ma u mnt
e s re e s in reverberatory hand
-
roas ti ng furnace wi t h
l evel hearth .

The wo rk done i n th i s class of furnaces i s shown i n Tab le 4 2 .

The amou nt of flue du st fo rmed vari es wi th the si z e of the co ncentra te-

treated ; i t i s however small and usually vari es from 1 to 2 p er ce nt Th e

2
, , ,
.

fuel co nsumed i s about 2 to ns coal or 4 co rds wood i n 2 4 hr The labor .

requi red vari es wi th the tonnage ; a fai r figure i s 2 men on a 1 2 hr shi ft for 9 -
.

to ns rawore i n a furnace wi th hearth 60 by 1 4 ft If the fur nace i s 80 ft long . .

and puts through 1 2 tons i n 2 4 hr an addi ti o nal m an will be requi red on a .

,

sh i ft .

If ore i s to be slag roasted i n a furnace wi th level h earth abo ut 60 ft long .

,

thi s has near the firebri dge a depressi o n or sump less than 1 ft deep i n whi ch .

the ore i s melted The co nsequence of thi s i s th at the ore i n fro nt of th e

.

thi rd and fourth doors from th e firebri dge i s pasty and if the fire has not been ,

carefu lly wat ch e d th e heat m ay be ex ce ssi ve up to th e fifth door N ot o nly does .

thi s i nterfere wi th a good roast but i t also renders the movi ng of the ore wi th th e ,

paddle a very arduous pi ece of work To counteract thi s i t has been and often .
,

sti ll i s the cu stom wi th su ch fu rnaces to colle ct the ore f rom th e th i rd and fou rt h

doors i n a heap i n front of the second doo r and to mel t i t down i nto the sump , ,

whence i t i s removed th rough the first doo r .

1
Met ChemE ng , 1 9 1 3, X 1, 44 7
mx
. . . .

1 E ng . Mi n J. .
,
1 9 1 0, Lxx , 4 49 ( von Bernewi tz) ; 857 ( Hoke) ; xc , 112 ( W ri ght) .
 S M ELTI N G LE AD ORE S I N TH E BLA S T F URN A CE

TAB LE 4 2 .
— RE VE RBE RA 1 0RY '
H AND R O AS TIN G -
FU RN ACE W I TH LE VE L H E ARTB

Length of h earth . .

W i d th of h ea rth .

Hearth area, s quare feet

Length of grate
W i dth
'
of grate
Grate area, sq uare feet

Rati o h earth t o grat e area

Sp ace abo ve firebri dge, length wi dth
and . .

Sp a ce a bove fluebri dge, length and wi dth .

Hei gh t of firebri dge above h earth

Hei gh t o f roof above firebri dge
Hei gh t of fluebri dge above hearth
Hei gh t of roof above fluebri dge
D ep th of grate belowtop of bri dge 1 7

Ch aracter of ore
Py m“g l n
: a e a

Co mposi ti on of o re
Screen size -
of ore (mesh ) . 12 and under

D ep th of charge near fluebri dge

O re st i rred (m i nutes) every

R o ast ed ore draw n every ( hours)

Tim e ore rem ai ns i n furnace (h ours)

T o ns of ra wore i n 2 4 hr .

Po unds of ore roast ed p er s quare foo t

h ea rth area 5 65
1 -

Charact er of roasted ore . Pulverulent Partly si ntered

Per cent . sulp h ur in roast ed o re . 2 —5 3

( ) S
a i 0 2 1 6—5 F e 2 8— 2 5 P b 2 1
.
— 2 —
5 Cu 2 3 Z n 4
—6 . S.33 A —
g 5 4 0 oz
2 . . . .
. Au o z. ( 6) Pyri te
Fe 37 S i 0
. 2 5 Cu 1 , Z n —
4 5;
. G al en a : Pb 45
—6 0 Z n 1 0 —12 ( c) B est roa st . . .

furnace of thi s de scripti on was i n operati on at Mi ne La Motte Mo

A ,
.
,
1

where a galena concentrate was slag roasted The hearth 55 by 1 1 54 ft .

, .

o n th e i nsi de w as sli gh tly i ncli ne d from flue to b ri dge m

,
ak i ng th e re spe ct i ve ,

di sta nces from hearth to ho ri zo ntal roof 1 5 and 2 2 in The top of the b ridge .

wall 2 2 46 in wi de was 9 i n above the hearth and 1 3 i n below th e roof The

, .
,
. . .

grate 1 0 ft by 2 1 i n was 3 ft 6 i n below th e top of th e bri dge thi s depth bei ng

, . .
,
. .
,

necessa ry on accou nt of the fuel u sed whi ch w as woo d Of spe ci al i nte rest i s ,
.

the co nstru cti o n of th at part of th e h earth where th e ore w as fu se d and of th e ,

b ri dge The form er was bui lt i nto a wrough t i ron p an resting on b ri ck p illars
.
-

betwee n whi ch ai r ci rcu lated freely I t was formed by a fu ll cou rse of .

fire br i ck and w
-
as sli gh tly co ncave
, The ai r cooli ng has p roved very efl ecti ve .
-

i n p reventi ng th e corro si o n of th e b ri ck A si m i lar re sult i s produ ced by the .

ai r fl ue passi ng th rough the b ri dge

-
Whe n th i s was at first constructed i n the .

usual way i t was found that th e mi ddl e part of the b ri dge was ap t to be eaten
,

1
Pri vat e co mmuni cati on fromJ . T . M onell , May, 1 89 1 .
1 50 ME TALLURGY OF LE AD

through by the slagged ore As a central wall di vi ded the fireplace i nto two .

parts the i dea was co ncei ved of closi ng the ai r flue i n the mi ddle and erecti ng
,
-

a sm all chi mney on the roof communi cati ng wi th both parts of the ai r flue ,
-
.

By thi s means a strong cur rent of ai r co uld be passed through th e flue Th e .

experi ment was a su cce ss and was adopted , .

The wri ter has used a w ater j acket i n fusi ng anti mo ni ate of lead i n a rever -

horatory furnace and has found that i t stopped all leak age at the bri dge
, .

The Mi ne La Motte furnace w as charged every 6 hr wi th 2 to ns of gal ena .

co nce ntrate to whi ch some sand had been added as aci d flux
,
The thi ckness .

of bed was 6 i n The galena ran from 4 0 to 70 p er cent Pb and from nothi ng
. .
,

to 2 5 per cent Fe and was crushed to pass a 1 2 mesh si eve The slagged ore
.
,
-
.

retai ned from 4 to 6 per cent S ; four men worked on a 1 2 hr shi ft and .
-
.
,

cord of wood w as burned p er ton of ore .

The f urnace at Bo nne Terre Mo w 1

as si mi lar to th e one at M i ne La Motte , .
, .

The roasti ng hearth w as 4 0 ft lo ng by 1 1 ft wi de the si nter h earth 1 1 ft square . .

,
.

and 8 i n deep The grate w

. as 7 ft by 2 ft 6 i n th e firebri dge 2 0 i n above th e
. . . .
, .

gr a te and 1 6 i n a bove the si nter h earth an d

. t h e roof 1 2 i n above t he br i dge ,
. .

At the flue end of th e furnace w -

as a br i dge 8 i n hi gh and the roof w as 1 6 i n .
,
.

above the fluebri dge T he ore t reated w as a gale na conce nt rate 5 mm and
.
,
.

smaller wi th Pb 72 Fe 4 Ca( Mg) O 5 S 1 5 p er cent I t was charged to a

, , , , .

depth of 4 i n sti rred on the roasti ng hearth every 3

.
6 hr on the si nter h ear th .
,

every hour and drawn every 6 hr I t remai ned 30 hr i n the f urnace and re
,
. .

tai ned 3 5 per cent S The furnace roasted 5 tons of rawore i n 2 4 hr or

. . . .

lb per sq ft of hearth area

. . . .

box — . Thi s furnace , nowab andoned , i s represented i n Fi g —

s 1 2 5 1 30
. . The mai n
i mprove ment of
furnace first e rected at the Omaha and Grant Work s
th e , ,

D enver Colo co nsi sts i n carryi ng on th e roasting on a hearth sep arate from
,
.
,

that on whi ch the slaggi ng or fu si ng takes p lace th e ore bei ng made to drop ,

through a verti cal flue from 2 2 to 2 4 i n hi gh on to the slaggi ng h earth The

, .
, .

hearth as seen i n Fi g 1 2 7 has the fo rm of a reverbe ratory smel ti ng furnace

,
.
, .

In or der to obtai n th e desi rab le su dde n change f rom the h i gh temperature i n the
slaggi ng hearth to the low temperatu re i n the roasti ng h earth the flue space ,
-

above the latter i s very mu ch e nlarged Thu s th e flam e on leavi ng th e slaggi ng .

h earth ( Fi gs 1 2 6 and 1 2 7) passe s through a flue 5 ft 6 i n by 1 ft 4 i n whi ch

. . . . .
,

on e nte ri ng th e roasti ng h earth i s sudde nly enlarge d to 1 7 ft by 2 ft 6 i n The . . .

su dde n i ncrease of area cau ses a correspo ndi ngly sud den decrease i n tempe ratu re ,

and thi s pro du ce s th e su dde n ch ange f rom pasty or fu se d to powdery ore A .

detailed descri pti on of th e fu rnace i s not necessary as the drawi ngs can be ,

under stood wi thout i t A few remark s however may be i n place .

, , .

The roasti ng h earth i s i n four separate planes di vi de d by 3 i n ofl sets whi ch ,

-
.
,

serve to keep the charge s apart The di stance between roof and h ear th i s .

thu s di mi ni shed by stages leavi ng the former hori zo ntal Thi s can also be , .

1
Pri vate co mmuni cati on fromG . Setz , March , 1 89 7 .
1 52 ME TALL URGY OF LE AD

do ne wi th hearth whi ch was advoca ted by H odges becau se

a si n gle i ncli ned , ,
l

the ofl sets fur ni shi ng poi nts of attack lead to th e i njury of the h earth and , ,

are not requi re d to separate one charge from another Only that part of th e .

roof above the lowest roasti ng h earth i s buil t of fire bri ck ; the rest i s of red bri ck -
.

I n the end vi ew ( Fi g 1 2 8) are see n fo ur op e ni ngs for adm i t ti ng ai r i nto th e

.

roasti ng hearth The addi ti o nal ai r requi red enters through the two doo rs
.

nex t to the flue wh i ch lead s i nto the fu se box the door li ds bei ng left sli g h tl y
,
-

,
-

aj ar The wo rki ng bottom of the fuse box used to be (and i s still some ti mes)
.
-

m ade of quartz sand seasoned wi th small amou nts of slag whi ch are ad ded
af te r the sand has bee n put i nto the furnace and h eated u ntil i t be comes sli gh tl y

si ntered on the surf ace Thi s bottom i s represe nted i n the drawi ng I t has. .

no t p roved as sati sfactory as w as expe cte d and has bee n gener ally rep laced ,

by a 9 i n fire b ri ck bottom bui lt sli gh tly concave The bottom rests on t wo

-
.
-

, .

arch e d roofs and i s th u s coo le d by ai r ci rculati ng below i t

, In th e firebri dge .

there i s on one si de of the ai r space a heavy cast i ro n bri dge plate to bea r - - -

the lo ngi tudi nal stress of the h earth The parts of the fur nace that wear out .

fastest are the flue leadi ng from the fuse box to the roasti ng hearth and th e -

fuse box i tself ; the former i s patch ed duri ng the run wi th rawclay mi xed wi th
-

some burned clay ; to repai r the latte r th e furnace has to shut down Water .

coo li ng of the se parts has no t bee n tri ed as far as the wri ter i s aware The ,
.

followi ng analysi s of a tomout quartz bottom easily explai ns howth e corrosi on -

has take n place : SlOg FeO MnO Pb p er c e n t A g an d .

,

Au 0 5 oz p er ton The co st of bui ldi ng a furnace i n Pueblo or D e nver as

. . .
,

sho w n i n the drawi ng s u sed to be The materi al s requi re d are : C ast ,

i ro n ,
lb ; wrough t i ron lh ; sheet i ron 4 00 lb ; old rai l buck stays
.
,
.
, .
,

1 0 000 1b ; red b ri ck
, fire bri ck
.
,
-

The tools requi red by each roaste r m an are: Tw o p addles ( blade 5 by 8 i n -

.

of i n i ron handle 1 0 or 1 2 ft long of 1 i n i ron) ; two rabbles ( h ead 3 by 9 i n

-
.
,
.
-
. .

of i n i ron handle 1 2 ft lo ng of A i n i ron) ; one sli ce bar ( 1 16 i n i ron rod

-
.
3
,
.
-
.
- -
.

flattened to a chi sel po i nt 3 or 4 i n wi de) and two door hooks The f ront -
.
, .

man has two scoops for the coal two sli ce bars three rabbles (head 4 by 9 i n
m
-

, , .
,

of i ron ; handle 1 0 ft long of

-
. i n i ron) and the ne cessary slag pots to .
-
.
,
-

re cei ve the slagged ore .

The m ode of wo rki ng a furnace wi th a fuse box used to be pretty uni fo rm a t -

the di fferent smelti ng works The ore crushed to pass a 2 mesh si eve was som e .
-

times dri ed on the roof of the furnace but ge ne rally i t was d ropped di rectly , ,

wi thout dryi ng through the hopper i nto the coolest part of th e furnace th e
, ,

wei gh t of the charge varyi ng from 2 400 to 3300 lb acco rdi ng to the thi cknes s .

of bed the ore can bear Someti mes the ore was Shoveled on to the hearth .

through the last two doors but thi s i s perm i ssi ble only when droppi ng th rough
m
,

a hoppe r i s im acti cable The charge w as sp read uni fo rm ly wi th paddl e and .

rabble to a thi ck ne ss of about 4 i n ove r the hi gh e st poi nt of th e h earth If t h i s . .

i s not separated by steps but merely i ncli ne d the charge i s so sp read th at i t , ,

shall li e i n f ront of the fi rst two doors There i t remai ned until slagged ore
‘

1
E ng . Mi n . J .
, 1 885, X L, 2 86 .
 S MELTIN G LE AD ORE S I N TH E BLA S T F URN ACE

was drawn from the fuse box when i t was moved down the furnace to i ts second -

p la ce the next hearth or i n f ront of the next two doors D uri ng i ts jo urney
on ,
.

t o the fuse box i t w as not only turned over wi th the paddle whi le bei ng moved
-

but raked wi th the rabble once twi ce or three ti mes accordi ng to th e i a , , ,

torvai of ti me betwee n the movi ngs e g every 1 % hr wi th 3 hr movi ngs , . .

, .
-
. .

B efo re the charge w as transferred to the fuse box the latter rece i ved some sili -

ci o ns ore to protect th e bo ttom After droppi ng the ch arge the fire w as urged . .

Th e h quefyi ng begins at the surface and much rabb li ng i s requi red to b ri ng ,

th e unfu sed parts from the bottom to the top Thi s w as do ne at i ntervals of .

$6 r for 1 5 m
h . i n at a ti m e at the begi nni ng later on for 1 0 mi n and toward the
.
, .
,

end for 5 Someti mes the fusi ng ore w

. as rabbled o nly once 1 % h r afte r drop ,
.

ping from the roasting hea rth Wh en th e charge was fused i t was draw n i nto .
,

slag pots -
Thi s m ay be done i n two ways ei the r all at o nce or i n three i nstall
.
,

m ents Th e former me thod was used wi th charges contai ni ng 1 0 per cent Pb

. .
,

the latter wi th those runni ng hi gh 50 and 60 per cent Pb for if th ey rem ai n any ,
.
,

length of ti me i n contact wi th the aci d hearth m ateri al they wi ll take up $ 102

and corrode the he arth unne cessari ly As soon as the front m an had draw n .
-

the slagged ore from the fuse box the roas ter m en d ropped the ne xt charge -

,
-

and began to transfer the other ch arge s do w nward unti l the hearth nea r the ,

flue w as em pti ed and ready for a newcharge When the fused ore had become .

co ld i t w , as dumped from the slag pots broken up and transfe rred to the feed -

, ,

floo r of the blast furnace I ts compo si ti on of course m ust vary greatly When . .

m ad e from mi xed sulphi de ores i t wi ll average : Si Oz 30 to 40 Fe 2 1 to 2 5 Zn , , ,

9 to 1 0 Pb 1 0 to 1 5
, S a bout 2 per c e nt , .

A furnace li ke the one sh ow n i n the drawi ngs roasted and fu sed i n 2 4 h r .

from si x to ei gh t ch arges ( varyi ng i n wei gh t from 2 400 to 3300 co nsumed

from 3 to 4 tons of bi tuminous coal half lump and half p ea and requi red th ree , ,

men i n a 1 2 hr shift one front man who attended to the fuse box and firi ng
— -
.
-
,
-

and two roaster m en w ho di d the work on the roaste r hea r th

-

,
If the ore i s not .

fused two men are sufi ci ent to do the wo rk The cost of roasti ng and fusi ng
,
.

wi th coal at p e r to n an d la bo r f o r 1 2 h r w a s ov e r $ 2,p er ton . .

In maki ng up sul ph i de ore beds for fusi ng furnaces two ki nds of ore have to -

be co nsi de red : galena concentrates free from or lowi n si lver assayi ng 50 to 60 ,

p er ce n t Pb a n d m i x
.ed arge n ti f e rou s,s u lph i de s c o ntai ni ng 1 0 per ce nt Pb a nd .

less .Wi th the former class of ore Cramer von Clausbruch sta ted that at the 1

Al tenau smelti ng and refini ng works ( H arz M ountai ns) he obtai ned the best
res ults i n treati ng hi s galena ores if the charge contai ned 1 5 per cent Si o, ,
.

and from 55 to 60 per cent Pb If there w as more Si 02 a bas e h ad to be added

. .
,

to cfi ect a complete slaggi ng at a reasonably lowtemperature ; i f th ere was le ss ,

some P hso ; rem ai ned u ndecomposed H e notes the i ntere sti ng fact that if .
,

the roas ted ore i s not completely slagged but retai ns p arts of su lphi des and ,

sul phate s th at have been o nly agglomerated the si lve r and copper wi ll be con ,

centrated i n th e agglomerated part One h undred parts of hi s charge gave .

85 p er ce nt of tho roughly slagged ore 1 0 p er cent of a m i x ture of slagged and

.
, .

1
Z t B erg H ittten S al
. . . . W . i Pr ,
. . 1 883, 10011 , p . 26; E ng . Mi n . J .
, 1 883, XXXV, 1 61 .
1 54 ME TALLURGY ’
OF LE AD

a gglomerated ore and from 2 to 3 per ce nt of unroasted agglomerated galena ,

.
,

the loss i n roasti ng varyi ng f rom 2 to 3 per cent The slagge d part of the cha rge .

co ntai ned one h alf of the Ag and only a trace of Cu wh ile the o th er h alf
-

of the Ag and all the Cu were concentrated in the rest of the charge .

‘’
At P ri b ram the bed s of galena concentrate contai ned 8103 2 0 Pb 3 5 p er
1
,

ce nt and Ag 76 oz per ton ; at Meche rni ch Si 02 2 2 Pb 58 p er cent Ag 4 oz

1
.
.
,
.
, , , .

per ton Analyse s of roasted ore are g i ven i n Table 4 3

. .

Wi th mi xed ore the p ri nci pal base to combi ne wi th the $103 of the sulp hi de
ore wi ll be Fe and the one next i n i m rt ance Pb Charges were m ade up
, m .

so that they mi gh t be readi ly fusi b le and sufli ci ently aci d not to corrod e the

bottom and si de wall s of the fuse box They sho uld contai n from 2 5 to 32 -
.

p er ce nt S i 02 an d t h e
. i ro n c alc ulated as,
F e be m ade to equ al th e S i O , .

Someti me s however proporti ons such as Si 02 1 0 to 1 5 Fe 2 0 to 2 8 Pb 2 0

, , , ,

to 2 8 p er cent were chosen o w i ng to the varyi ng amounts of lead and i ron

.
,

sulphi de ore on hand from whi ch the charges had to be made up It w as not ,
.

common to add li m e to a charge contai ni ng lead .

82 Reverberatory H and roasti ng Furnace w

. i th Sinter H earth — Thi s fur -

nace whi ch i s still found here and there re sembles ve ry much th e one wi th a
, ,

slaggi ng h earth the m ai n di fi erence bei ng that on account of the lowtempera

, ,

ture requi red for si nteri ng the si nter hear th has the same wi dth as the roasti ng ,

h earth and i s separated f rom the latter by a step say 8 i n hi gh and that the , .
,

roof of the si nter h earth has le ss pi tch .

The mai n di m ensi ons of su ch a furnace are: Ro asti ng hearth 74 by 1 4 ft ; ,

.

si nte r h earth 1 0 ft 4 i n by 1 4 ft ; grate 9 ft 9 i n by 2 ft 1 0 i n ; firebri dge 9

,
. . .
,
. . . .

ft 9 i n by 1 ft 6 i n ; h ei gh t of firebri dge above grate 1 1 i n above si nter h earth

. . . .
,
.
,

1 1 i n ; hei gh t of flue ab ove firebri dge 1 2 i n at si des and 1 8 i n at cent e r; h ei gh t

.
,
. .

of step separati ng si nte r and roasti ng hearth 8 i n ; hei gh t of flue leadi ng from , .

si nter to roast i ng hea rth the same as th at of roasti ng hearth vi z 1 7 i n at , ,

.
,
.

si de s and 2 5% i n at cente r An ore charge cru shed through a 2 mesh si eve

. .
,
-

and co nsi sti ng of pyri te w i th gal ena and blende contai ns Si 02 1 0 to 2 5 Fe 2 0 , , ,

to 30 Pb 2 to 1 5 Cu 1 to 3 Zn 2 to 1 0 S 2 8 to 44 p er cent ; Ag 1 5 to 3 5 oz
, , , ,
. .
,

and Au up to 1 oz p er ton At the E ile rs plant Pueblo Colo a charge usually

. .
, ,
.
,

ran Si 02 1 5 Pb 1 5 Fe 3 5 Zn 8 S 5 p er cent A ch arge remai ns 30 hr i n

11
, , , , . .

the furnace i s sti rred on the roasti ng hearth every 94 hr on the si nter hear th
,
.
,

every hr draw n every 3 h r and retai ns 2 to 3 per cent S

. Si ntered ore .
,
. .
,

whi le i t i s bei ng drawn from the furnace i nto a slag pot i s usually pounded -

down wi th an i ron di sk 1 ft i n di amete r attach ed to a handle ,

.
,
.

Th e fu rnace pu ts through i n 2 4 hr 1 2 to ns of rawore requi res three m en o n .

,

a sh i ft and co nsumes about 3 to ns of co al

,
.

83 Products of ReverboratoryH and roasti ng Furnaces — The two pro duct s -

obtai ned by roasti ng are roasted ore and flue dust The compo si t i o ns of some -
.

1
Zdrahal, Oester J ahrb , . . 1 880, XXXVIII , p . 1 0.
1 B erg H atten . mZ . .
,
1 8 75, XXX IV, 1 2 9 .

1 Gilbert ,
F C . .
, May ,
1 904 .
1 56 M E TALLURG Y OF LE AD

ores runni ng hi gh i n lead that have been agglomerated or completely slagged is

gi ven i n Table 4 3 .

An analysi s of cry stals of slag roasted galena ore ri ch i n zi nc gave accordi ng -

to H eberdey 8102 1
,
PhO ZnO FeO CaO trace MgO ,

p er ce nt ; p g
s r . . .

The amou nt of flue dust carri ed 03 wi th the gases i s about 2 p er cent and
-
.
,

i s p racti cally all co llected i n du st chambers ; of the metal volati li zed i n fu si ng -

very li ttle if any i s recovered unless a Cottere ll preci pi ta tor is provi ded , .

Fl ue du st from furnaces if the ore i s si mply roasted has a brownish color ;

-

, ,

i f slaggi ng i s carri ed on i t i s gray from volatili zed lead and zi nc , Thi s gray .

du st i f i t co ntai ns not le ss than from 1 to 2 per cent Zn has wh en moi ste ned
,
.
, ,

the property of soli di fyi ng to a hard mass Thi s i s no t the case w i th brow n flue .

du st Th e soli di fyi ng i s probably caused by th e anhydrou s z i nc su lph a te be

.

comi ng hy drate d I ts b i ndi ng property i s strong enough to allow the m i xi ng

.

i n of 2 5 p er ce nt of non bi ndi ng materi al when i t sti ll w

. ill fo rm a har d bri ck
-

when molded I n fact the gray dust when moi stened forms a pasty mass
.
, , ,

requ i ri ng a sti fi eni ng i ngre di e nt to perm i t i ts bei ng molded at all Th e com .

po si ti o ns of some samples of flue du st are gi ven i n T ab le 4 4 -

.

The large quanti ty of gold show n i n so me of the analyses i s probably due to

gold beari ng pyr i te concentrate s from gold mi lls used as i ron fl ux and to tellu
-

ri de gold ores .

84 Blast Roasti ng, General

.
1 — The ai mof blast roasti ng i s to roast and ag .

glomerate fine ly di vi ded metalli c sulphi de by mea ns of forced draft I n .

order to accompli sh th i s i t i s necessary that the parti cles brough t to i gni ti on

, ,

temperatu re be separated from one anoth er and be i n contact wi th fluxes so tha t

,

th e grai ns of sulphi de m ay be completely o xi diz ed and that the h ea t ge nerated ,

thereby may be suffi ci ent to ca u se the oxi des fo rmed to comb i ne wi th th e

fluxes and form fusi ble mi xtures or compou nds whi ch bei ng pasty at the p re ,

vaili ng tempe rature cohere to one ano ther and form a lump of m , ore or les s

scorified m ateri al .

The advantages of blast roasti ng over the usual oxi di z i ng roasti ng have been
so great that th e former p rocess has ahnost wholly replaced the la tter i n lea d

smel teri es Some of the advantages are: Oxi dati on and elim
. i na ti on of sul
phur combi ned wi th agglomerati on of ore accompani ed by decrease i n volatili
,

zati on of metal and redu cti o n of cost of plant and of trea tment
,
Wi th regard .

to sub sequent smel ti ng i n the blast fu rnace : Increase of smelti ng power to as

mu ch as 1 00 per ce nt o wing to absence of fines i nti mate m i x ture of ch arge
.
,

compo nents i n and poro si ty of b last ro aste d cake or si nter decrease i n req ui re ,

ment of coke and of pressu re of blast and wi th the last de crease of loss of metal , , ,

by dusti ng and volatiliz ati on .

1 Kroupa, Oesterr Z t Berg H a . . . . 89 3 , x LI , 1 3 8

, 1 .

1 Hofman General Metallur

“
, gy,
”
1 9 1 8, 4 1 1 ; Tr A I . . . M . E .
, 1 9 1 0, X LI , 739 .

I ngalls, op ci t , 1 906, XXX VI I, 62 7

. . .

Gui llet, Rat Mtl , 1 9 1 1 , VIII, 584

. . .
 S M E LTI N G LE AD ORE S I N TH E BLAS T F URN ACE

T AB LE — AN ALYS ES or FLUE DU ST FRou RE VE RB E RATORY HAND R OASTIN C FUR NACE S

44
- -
.

1 —4 0
9

23 23 20 37
- -

o .
5o

None

4 36 1 63

8 23 7 95

1 34 0 60 Trace
3 4 0 3 75
1 46 3 27

( a) Koerna nn Z t B erg B atten S al Wes i P r 1 883 . . 1 22 7 ( b) H eri ng

. . . . . . m . . h
Di e Verdi c tung des
H fi t tenrauch ee S tut t ga rt 1 8 8 8 p 3 4 ( c) Mann Oester J a hrb 1 89 0. XXX IX . ( d) Li vi ngsto ne
"
. 15.
.

mf
. . . . . .

pri vat e notes 1 89 6 ( e and f) Iles p ri vate notes 1 89 6

. .
( g) Average of 1 0 yea rs , . . .
( II) Fro usi ng fur
naces ( i ) Fro si nteri ng urnaces
. m
( j ) Fro m roasti ng urnaces f .
'
f .

Th e earli est record of the practi cal appli cati on of the p ri nci ple of forced
ro asti ng i s th at of Rosw who descri bes operati ons carri ed on i n Spai n i n a
1
ag ,

spheri cal ket tl e An earli er i nstance di fl erent as to details i s that by Was

'

.
, ,

si li a di
1
who di scusses some work carri ed on i n Asi a Mi no r i n 1 895
,
.

B las t roasti ng became i mportant o nl y wi th the advent of th e H u nti ngto n

H eberlei n p roce ss i n whi ch a gale na co ncentrate m i xed wi th cru sh e d li me sto ne
,

i s rough ro asted i n a reverbe rato ry fu rnace mo i ste ned and th en b lo w

-
n in a , ,

sph eri cal kettl e For th i s p ro cess the term Li me Roasti ng w

‘1
. as u sed for some

ti me In the development of the p racti ce of blast roasti ng i t was fou nd that

.

“
1 Fré my ,
EncycIOp édi e Chi miqu e,
”
Dunod ,
Pari s, 1 884 , secti on 1 ,
vol .
5, p . 243 ; E ng .

Mi n . J .
, 1 1
9 ,2 X CI I , 750 .

1
Tr I nst M i n Met — XXII ,
. . . .
,
19 12 1 3, 70 2 .

1 Ingalls, Eng Mi n J . . .
, 1 90 5, LXXX, 40 2 .
1 58 M E TALLURG Y OF LE AD

li mewas not of vi tal i mportance ; the term Pot Roasti ng was therefore an im 1

provement Wi th the advent of the Dwi gh t Lloyd roast si nteri ng machi nes
.
- -

the kettle or pot ceased to be an es senti al factor ; the broad term Blast Roasti ng 1

has replaced the two precedi ng desi gnati ons al though th ey are still used occa ,
” “
Te rms li ke bessemer roasti ng and blast and dow n draft si nte r
si onally .
-

”1
i ng have been suggested but not adopted ,
.

The se cond step i n b last roas ti ng w as tha t ta ke n wi th the C armi ch ae l

Bradford process i n whi ch a m o istened m ix ture of rawgalena concentr ate and

,

dehy drated gyp sum i s blown i n a pot .

The thi r d m o di ficati o n was that of the Savelsberg process in whi ch cr us hed ,

rawgale na i s m i xed wi th li mesto ne moi ste ne d and blown i n a sphe ri cal kettle , ,
.

The hi gh calo rific power of galena conce ntrate di mini shed by a rough roast -

i n the H unti ngton H ebe rlei n pro ce ss i s redu ced i n the Bradford C arm
-
i chae l ,
-

and the Savelsberg p ro cesse s by large addi ti o ns of gyp sum and li mes to ne .

These th ree p ro ce sses we re p roposed for the treatment of sulphi de lea d ore .

They difi er i n the preparati on of the charge but are very mu ch ali ke i n th e ,

manner of blowi ng i n that they use a deep spheri cal kettle wi th b last i nlet
,
-

at the bottom charge the ket tl e blow the conte nt and di scharge the ca k e
, , ,

that has been formed They use Up draft and are I nterm
— i ttent. .

The fourth and last step i n blast roasti ng i s that ta ken wi th the D w i ght
Lloyd pro cess whi ch at the start w
, as not confi ned to lead o re s and he nce not

to certai n fluxes or diluents The apparatus di fi ers radi cally from i ts p re de .

cessors i n that a thin layer of ore mi xture on a traveli ng gr ate i s made to pass

over a stati onary su cti on box where after i gni ti on on the su rface down draf t -

, ,
-

cau ses the roast to progress do w nward and the traveli ng grate di scharges th e ,

blast roasted ore i n the form of cakes into a re ce i ver The leadi ng fe atures .

of th e p ro ce ss are therefore a thi n layer of ore Dow n draft and a Conti nuous ,
-

Operat i on .

The great success of blast roasting lea d ores has been the cause of e x tendi ng
th e ope rati o n to other sul phi des e g to concent rates of sulphi de coppe r and ,
. .
,

copper ni ckel ores and to matte i n p repari ng them for b last fur nace t rea t m
-

,
ent , .

Arse ni des such as spei ss have been treated successfully as have oxi de s of i ron
, , ,

and flue dust whi ch however requi re the ad di ti o n of heat produ ci ng m

-

, a te ri al ,
-

i n th e fo rm of sulphi de or carbonaceous fuel Wi th oxi des si nteri ng i s th e mai n .

,

object and desulphuri zati on only i nci dental .

—
85 Th eory of Blast Roasti ng Th e re have been publi shed many spe cula
.

ti ons about the reacti ons that mi gh t take place i n blast roasti ng espe ci ally i n
1
,

regar d to p o ssi b le i nteracti ons of PbS PbSO4 PhO CaO and CaSO 4 and the , , , ,

1 Mi n 5 6 Press 1 906, XCI II 51 1

Austi n, . .
, , .

1 D
w
i gh t, E ng Mi n J , 1 908, LXXXV 64 9
. . .
, .

1
Met Chem E ng , 1 9 1 0 vm, 1 3 7 2 2 2
. . .
, ,
.

1
Sum mari es : Prost Rev Un Mi n , 1 907 .
, . . .
, XVIII , 303 .

Kroup a, Oesterr Z t Berg H atttenw, 1 908, LVI ,

. . . . 2 76 .

E di t or, E ng Mi n J , 1 909 , LX XXVI I , 6 1 3

. . . .

m “
G eli n—Kraut, Handbuch der anorgani schen Che i e, m 1 91 2 , vol .
4 , p art 2, p 33. .

Ri ch ter and Banni st er, see bel ow .

1 60 ME TALLURCY OF LE AD

°
CO z+ 850 does no t take place (Doeltz) ; PbO + CaSO4 +
h a
e =tCa —
does not take place
O a I Sog
-
.
1

The observati o ns of Pe rcy and H ut chi ngs as well as the curves of Banni ster
( g 33)
F i . s h ow t h at i n u si ng C aO as fl u x t h ere t ake s p la ce an e xot h erm i c rea c

ti on the character of whi ch i s not known P racti cal experi ence also teaches .

that wi th lead ore s li me has a favo rable i nflue nce upon desulphuri zati o n but ,

the cau se of i t has no t been ascertai ned .

To wh at e xtent CaSO ‘ i s fo rmed i n a blast roast i s not kno w n Banni ste r i n .

usi ng CaO i n hi s m i xtu re obtai ned large amounts of CaSO4 ; but i n usi ng CaCO ;
on a large scale i t i s beli eved that ju dgi ng by the expe ri ence i n roasti ng sul ,

p h i de coppe r co n c e n t ra te s i n a M c D ou ga ll fu rn ace 2
t h e CaCO ; will be fou n d ,

unchanged or only li ttle al tered i n the rough roasted charge In b last roasti ng -
.

CaSO 4 m ay be fo rm
°
ed Thi s i s decomposed by heat alone at 1 2 00 C
.
1
The .

deco m po si ti on by Si 02 as shown by ,
begi ns
In the presence of galena the decom
°
at 1 000 C and i s fini shed at 1 2
.

°
posi ti on 6CaSO4 + 6Si Og+ 2 PbS 6CaSi Os+ SSOz+ 2 PbO begi ns below 800 C
, ,

i s complete at 1 000 and wi th BaSO , at 1 1 00 th e SO . set f ree

0
i s completely di sso ci ated at 1 000 1
i nto 802 and O ; i n a cooler part of the
charge SO, and 0 m ay recomb i ne and the 80: forme d have an oxi di z i ng ,

eflect La
. s tl y C a S O4 + 2 Fe3 30 = CaO 2 F0203 SO3 + O begi ns at 1 1 00 C and .
-
°
.

°
i s fini shed at 1 2 50 C ’
.

86 Pri nci ples Governi ng Mak e up of Charges

.
1 — In the preparati on of a -
.

ch arge for blast roasti ng be i t up or do w n draft certai n requi reme nts have to
,
-

be f ulfill ed if there i s to be a sati sfactory eli mi nati on of S and i f the powdery

, ,

mi x ture i s to be converted i nto a more or less si nte red porous cake .

The heat furni shed by oxidati on mu st be sufi ci ent for agglomerati on and
not i n any gre at e xcess over the amount requi re d Comp ari ng the quanti ti es .

of heat li b erated by oxi dati on per atom or 1 6 g 0 of the u sual charge com .
-

p o n ents gi ve s th e fo ll ow i ng :

(Zn, O) cal .
; cal .
;
( e, O)
F cal .
; 03 16

( , 0)
N 1 61 15
00 cal -
i
= 34 r63° ca l -
i
}S( Sb21 03) 6
551 30 C3 14 0 6
3 1 3 0 cal -
i
cal .
; (C , O ) cal .

( , o)
Ph cal .
;

1 H ofman Mostowi tsch loc ci t

-

, . .

1 Hof man Metallurgy of Copp er 1 9 1 8 1 04

, , , .

1 Hof man W anjukow Tr A I M E 1 9 1 2 X LI II

-

, . . . . .
, , , 5 23 .

1 Hofman Mostowi tsch op ci t 1 908 XXXIX 64 5

-
, . .
, , , .

1
Sch li tz,M etal lurgi e, 1 9 1 1 VI II 2 2 8 , .

1 Hof man General Metallurgy 1 9 1 8 4 0 5

“
,
”
, , .

1
Hof man Mostowi tsch loc ci t
-

,
. .

1 Hof man E ng M i n J 1 9 1 1 XCI 4 8

,
. . .
, , ,
.

Pul si fer M et Chem E ng 1 9 1 2 X 1 53 2 0 7

,
. . .
, , , ,

Klugh , I ron Trade Revi ew, 1 9 1 5,

LVII , 83 5 .
 S M E LTI NG LE AD ORE S I N TH E BLAS T F URN A CE

Thi s ow s th at the oxi dati o n of metal evolves a mu ch larger amount of

sh

h ea t th an does that of S A lowgrade copper matte or one that i s ri ch i n .

-

Fe w, i ll develop w i th the same velo ci ty of reacti o n a hi gh er tempe rature

, ,

than a hi gh grade whi ch runs lowi n Fe The same i s the case wi th a lead
-
.

matte when compared wi th a galena concentrate The charge for a materi al .

developi ng much hea t has to be made up di fferently from one whi ch develops
li ttl e .

Th e speed wi th whi ch the oxi dati on takes place i s ano ther factor If i t i s .

too great si nteri ng wi ll take place before roasti ng i s fini shed wi th the resul t that
, ,

the ch arge becomes ti gh t and does not allow ai r to pass freely and that si ntered ,

parts enclose rawsulphi de .

W i th regard to lead charges i t i s observed by Mostow i tsch that a bi sili cate

1
,
-

mix ture and one of lower degree of sili cati on runs hot and tha t the desulp huri
, ,

zati o n i s good ( 2 p er cent S and le ss) ; but th at th ere i s left unagglom . erated a

large part of the charge ; that th ere i s set free me ta lli c Pb from the acti o n of
PbSO 4 or PbO upon PbS and that there i s present uncombi ned PhO i n the pro
du ct . The globules or vei nlets of Pb tough en the cake and the PM makes dust ,

when the cake i s broken or handled Wi th an aci d mi xture bi si li cate or hi gher .

,
-

si nteri ng begi ns before roasti ng has progressed sa ti sfacto rily hence desulp huri ,

za ti o n i s bad ( 5 per ce nt 8 and hi gher) The cake breaks readily and makes
. .

no d us t but retai ns much sulphi de S

,
-
.

There are seve ral ways of correcti ng the heati ng efiect of an excess of sul
p h i d e O n
. e i s to ad d an ex tr a am ou n t of w a te r to the charge e g 1 5 as agai nst , . .
,

the usual 5 per cent The effect of water i n the charge i s three fold : I t coun
.
-

teracts dusti ng ; i t keeps down the temperature on account of th e h eat ab sorbed

by i ts evapo rati on; i t keep s the charge open owi ng to the spaces left unfilled
whe n i t has been exp elled Th us w i th ore 16 i n and sm alle r an addi ti on of
m
. .
,

5 per c en t w a te r m ay be s
.u ci ent where a s a fi ne or flota ti o n co n ce ntr a te ,

may requi re as mu ch as 1 2 per cent water i f i t i s to work sati sfactorily . .

A second method i s to rough roast the ore as i s the case wi th the H unti ngton -

H eberlei n pro cess i n order to convert some sulphi de i nto sulphate and oxi de
,
.

T h i s not only di m i ni shes the calo ri fic power of the ore but adds some oxi de ,

whi ch becomes a di luent and acts as i f a correspondi ng amount of extraneou s

matter h ad beenadded to the charge .

The ad di ti on of a di lue nt to the rawsulphi de to reduce the cal ori fic power as ,

i s th e case i n the B radford C arm i chael and Savelsberg processes form -

s a remedy ,

whi ch qui ckl y reaches an econom i c li mi t wi th regard to the sub sequent

sm elti ng i n the blast furnace If the speci fic heat of the dilue nt i s hi gh .
,

it w i ll be mo re efli ci ent than if i t i s low .

R etardi ng the process by the use of ai r weakened i n i ts oxi di z ing power by

t h e adm i x tu re of waste fuel gases has bee n sugge ste d by Savelsberg but has -

not bee n tri ed .

The statement of Ri ch ter that the character of th e gangue h as li ttle i nfluence

2

1
Tr A I . . . M . E .
, 191 6, LV, 744 .

1
Loc . ci t .

ll
162 M E TALLURGY OF LE AD

in blas t roasti ng b ased upon roasti ng is made i n an assay mu e experi ments -

m
whi ch showed that oxi da ti on was hastened about equally by the 1 5 di l uents
he t ri ed namely li me stone i ro n oxi de gypsum ca usti c li me dolomi te bari te
, , , , , , , ,

wi the ri te baryta cer ussi te anglesi te lead and copper blast furnace slag
, , , , .
-

ground b ri ck si li ci ous gangue and blue billy (i ron ore ) The experi ments
, , .

of Banni ster wi th CaO $ 102 PbO I CaO CaCOz CaSO. Mgo F0203
1
, ,
- -

, , , , ,

H gCaOg tell another story

,
As far as the me chani cal effe ct of holding apart
.

the sulphi de parti cl es and th e reby favori ng the speed of a roast i s co nce rned ,

the stateme nt of Ri ch ter holds true ; but the thermal and chemi cal be ha vi o rs
of the addi ti ons to a charge have to be well consi dered I t i s essenti al for a .

blas t roast that complete o xi dati on of the sulphi de be accompani ed or close ly

followed by si nte ri ng or fusi ng The latter takes place at a tempe rature sli gh tly .

hi gh er than the former ; wi th si li ca te mi xtures the two curves usu ally run
parallel The specific heat of the gangue or flux must be of such a quanti ty
.
1

as to ab so rb any e xcess heat gene rated by the fo rced ro as t ; i t ough t to act as a

th ermal balance wheel whi ch equali zes t he temp eratu re and holds i t at a poi nt
-

at whi ch roasti ng and si nteri ng can pro ceed at the desi red rate and i n th e re

qui red degree If th e speci fic hea t i s too low the temperatu re ri ses too q ui ckl y
.
,

and the charge fuses before i t i s sufli ci ently de sulph u ri z e d ; i f too hi gh too ,

much hea t i s absorbed and th e temperatu re of the sulphi de i s kept too lowfor a
,

perfect roast and espe ci ally for the desi re d si nteri ng wi th the result that part o f
the charge i s i mpe rfe ctly ro asted and re m ai ns pu lve rulent The followi ng sub .

sta nces are ar ranged appro xi mately i n th e order of thei r speci fic hea ts th e
1
,

first havi ng the lowe st value : lead oxi de cerussi te anglesi te bari te coppe r oxi de , , , , ,

wi th e ri te manganese oxi de i ro n oxi de i ron si li ca te calci um sulpha te basi c

, , , , ,

copper carbo nate alumi na si li cate lowi n i ro n ho rn blende li mesto ne sand

, , , , ,

stone ground bri ck dolo m

,
i te clay copper and lead blast furnace slag and
, , ,
-

gy p sum .

As regards the chemi cal efl ect of the flux i t i s essenti al that the m i x ture
have a compo si ti on whi ch si nters at a low temperature fo rmi ng si li ca te or ,

ferri te or bo th For example wi th lead ores the compo si ti o n i s u sually one

.
,

whi ch wi ll resul t i n a si ngulo sili ca te of low formati on temperature If the -

.

percentage of metalli c sulphi de i s too low rawsulphi de or carbo n will have to ,

be added to the charge A charge ri ch i n Pb may contai n from 9 to 1 2 p er cent

. .

S one th at i s poo r i n Pb as mu ch as 2 0 per cent

, .

The si z e of grai n of th e ore w i ll be the sam e as that whi ch has been fo und to
be best for an o rdi nary roast e g for galena about 8 mesh Di fli culti es ari se in , . .
,
-
.

the trea tme nt of flota ti on co nce ntrates The se have bee n ove rcome i n part .

by puggi ng wi th coarse co ncentrates i n quanti ti es to be found by experi me nt .

The grai n of the flux ough t to be coar ser than that of the ore; wi th a gale na
charge the si z e i s about 4 mesh Wi th mixed ores the largest permi ssi b le
-
.

1
Loc . ci t.
1
Mosto w i tsch p ri vate com muni cati on, 1 9 1 0
,
.

G ui ll emai n M etall urgi e 1 9 1 0 V11 599

, , , , .

1
Landol t Bernstei n
“
Roth , Tabellen Sp ri nger, Berlin,
- -

, 1 91 2, 754 .
1 64 M E TALLURGY OF LE AD

88 Rough Roasti ng of Metal li c Sulphi de for Blast Roasti ng O ri gi nally

.
—

rough roasti ng of sulphi des preparatory to blast roasti ng as confine d to th e w

H u nti ngto n H eberlei n proce ss ; later wi th the enlargement of the field of blast
-

roasti ng the prep arato ry t rea tment w

,
as p racti sed i ndepe ndently of the H 81 H . .

p ro ce ss It therefo re de serve s a separate di scu ssi o n

. .

Th e ai mi s to re du ce by one half the S co nte nt of the mi x ture whi ch u sually - -

co ntai ns from 2 0 to 2 2 p er ce nt S . .

The fu rnaces used at first have been some mo difica ti o n of the Brunto n
Revo lvi ng hearth Fu rnace desi gned for the treatm
-
ent of ca ssi teri te co nce ntrate s .

I n E u ro pe the H u nti ngton H eberlei n Furnace a flat ci rcular hearth suppo rted -

by a shaft and large siz e rolle rs and dri ven by chai n and spro cket whee l was
-

,
-

used i n co nnecti on wi th th e H H pro cess I n the U ni te d S ta tes th e Go d . . .

frey Furnace i s common; i n a fewi nstances the H ol thofi Revolvi ng H earth h as

been substi tuted ; recently the Wedge Furnace has become the ri val of the Go d
frey and thi s especi ally i n the rough roasti ng of matte The di scussi on wi ll be
, .

co nfi ne d to these f our fo rm s .

89 B runton Fum
. ace
1 —
Th e fu rnace i s represente d in Fi gs 1 3 1 and 1 3 2
. It . .

i s a reverberatory fu rnace wi th ci rcular rotat i ng h earth a fireplace b centra l , , , ,

feed hOpp cr e fixed rabble teeth g di scharge doo r g and re cei vi ng bin h
-

, ,
-

, ,
-

, , ,
.

S cale of Foot

“
o l
fi
z at s s
b
vs s iou n
ul a - J
FI G S . 1 31 and 1 32 — . B runto n urnace f .

The sli gh tly o

ft i n di ameter of
c ni cal hearth ,strength e ned a, 1 2 .
,
is boi ler i ro n, -

wi th radi al ri b s
and covere d wi th b ri ckwo rk ; i t i s carri ed by a ve rt i ca l

shaft whi ch i s ro tate d a t th e rate of 1 r p m through a cog wheel and beve l . . .

-

geari ng i ; th e sh aft of the bevel pi ni on i s conne cte d to that of the wat e r

,

wheel A through two meshi ng spur wheels The flue whi ch carri es ofl th e
, ,
-
.

gases i s not shown the chi mney i s i ndi cated The ore fed through hopper e
,
.
, , ,

stri ke s th e b lade s of th e fixe d rake f i s t ur ne d ove r as the h earth revo l ve s , , ,

and move d gradu ally f rom th e ce nter to the peri phery to be di scharge d

1
Moi ssenet, Ann Mi n 1 858 XIV 2 2 3 ; Berg H fl ttenm Z 1 859
. .
, , , . . .
, ,
X VIII , 3 55 .

“Di Metallhil ttenkunde ” S ri n er Berli n

Balli ng C A M e ,
.
, .
p g ,
.
, , 1 885, p 51 7 . .
 S M ELTI N G LE AD ORE S I N TH E BLAS T F URN A CE

through the door g i nto one of the two rece i vi ng bi ns h the di recti on bei ng
, , , ,

governed by the posi ti o n of the deflecti ng sli de l The furnace trea ts

,
. lb .

cassi teri te conce ntra te i n 2 4 hr wi th a fuel consump ti on of

. per cent .

coal t he temperature bei ng ke t low

, p .

0 Godfrey Furnace — Thi s furnace i s represented i n Fi g s 1 33 1 37 as con

9
-
. .

stru cte d by the Stea rns Roge rs Mfg Co of D e nver Co lo

-
. . for the leadi ng sm el t
,
.
,

eri es of this co nti ne nt u si ng th e H unti ngton H ebe rlei n p ro cess The drawi ngs
-
.

bri ng out clearly the gre at ch ange s that have been m ad e i n th e or i gi nal de
1 66 M E TALLURG Y OF LE AD

sign of Brunton The plan Fi g 1 33 shows the annular wall a of the furnace
.
, .
, , , ,

2 9 ft 4 i n and 2 6 ft 4 i n i n di amete r and th ree doo rs A to fu rni sh access to th e

. . . .
, ,

hearth ; the firep lace b 4 ft 6% i n by 3 ft o n the ri gh t si de ; chute c and s to r

, , . . .
, , ,

M es srs

’
age bi n, c ,
fo r ro asted ore o n th e left ; dri vi ng shaft ,
d,
w i th t i gh t and loo se p ulle ys ,
v and 10, a t the upper and doo r B at the lowe r si de ente ri ng b eneath the hea rth
, , ,
.

On the roof , k are see n th e ore h0 r e wi th fee d co ne f cast i ro n gi rde r g

'
, pp e -

, ,
-

, ,
-

, ,
1 68 ME TALLURGY OF LE AD

e ters wi th washers and nu ts The ci rcular openi ng near the top of a r abble
c n ,
.

fur ni shes a means of i nserti ng an iron hook for r ai si ng and loweri ng .

The hearth bu il t of 7 i n bri ck on a 14 i n steel p late strength ened by 1 2 i n

,
-
.
,
-
.
-
.

radi al I beam s i s suppo rted at the center by sp i ndle l revolvi ng i n step box
-

, , ,
-

At a di stance of 8 ft from the center i t i s carri ed by an i nverted ci rcular rai l .

,

n traveli ng on four ro llers 0; at the ci rcum

,
fere nce i s flange p whi ch reaches i nto , , ,

sand seal q ( see also Fi g

-

,
To th e I beam s stre ngtheni ng the steel bottom .
-

plate of the h earth i s attached cog wheel r wh i ch i s dri ven by pi ni o n wheel s -

, , , ,

as shown i n Fi g 1 36 (secti o nal elevati o n parallel wi th the dri vi ng sh aft d)

.
-

,
.

The pi ni o n shaft carri es at the lower end bevel gear t meshi ng wi th bevel pi ni o n
- -

, ,
-

n the dri vi ng shaft of whi ch d carri es ti gh t and loo se pu lley s a and w Fi g 1 36

, , , ,
. .

shows also the m anner of suppo rt of feed hopper e whi ch i s angled to I beam i -

, ,
-

, .

I t wi ll be no ti ced that hea rth k i s place d hi gh 7 ft 2 i n above th e , , ,

. .
,

floor li ne i n or der to permi t di schargi ng i nto bi n c Fi g 1 34 and deli ve ri ng

-

, , ,
.
,

from thi s into cars whi ch are to be hauled to the ore beds or blast ro asti ng -

apparat us .

The wei ght of the iron work of a furnace li es between and

lb and co sts f o b P ueblo Colo from $2 2 00 to $2 500

. . . For the erecti on
.
,
.
, .

there are requi red 4 5 cu yd concrete 4 700 red bri ck and 2 000 fire bri ck . .
, ,
-
.

The co st of ere cti ng ei gh t furnaces w as : E xcavati o n and filli ng $900 ; bri ck ,

work and co ncrete $9 600 ; i ron work and erecti o n or , i n all ,

.

Thi s makes the ap p roxi m Me co st of a furnace set up $4800 ( before the present
adv ance i n p ri ce s) .

The general arrangement of a Godfrey plant i n co nnecti on wi th the H unti ng

- —
ton H eberle i n p rocess i s gi ve n i n Fi gs 1 4 5 1 4 7 . .

Anothe r form of B runton fu rnace has been descri be d and i llustrated by

Blakemore 1
.

In runni ng a furnace the ore charged at the center i nto hopper e and fed , , , ,

through tele scopi c feed tube f co ntro lled by a hand wh eel falls upon the hearth -

, ,
-

and fo rm s a co ne The rabble and fee d blade s nea r the cente r remove th e
.
-

ore and spread i t ; the ne xt fo llowing b lade s tur n i t over and move i t outward so

that i t travels from center to peri phery i n a spi ral curve where i t i s di scharged
'
by means of an outer fixed rabb le blade thro ugh ch ute c i nto bi n c -

, , , .

The Bru nto n type of furnace fur ni she s an exce llent m eans i n a reverberatory ,

furnace of comparati ve small hearth area of subje cti ng an ore for a co nsi derab le ,

ti me to a u niform oxi di z i ng roast u nder co ndi ti ons of temperature whi ch are

under co ntrol .
.

Tab le 4 5 gi ve s data of the work the f urnace does i n rough roasti ng -

sulphi de m ateri als befo re they are added to b last r o asti ng charge s .

Th e two examples gi ven represent goo d ave rage work carri ed on at present .

I t i s si mi lar to that of earli er record s of Murray U tah ; E ast H elena Mont ;

1 1
, ,
.

1
Tr I nst . . Mi n .M et ,
1 89 8—99 , VII , 3 2 3 .

1
Ingalls, E ng Mi n J 1 90 7, LXXX IX , 5 7,
2 575 Bri ns mad e, Mi nes and M i nerals 1 90 7 ,

m
. . . .
, ,

, 21 6 .

1 Newhouse , Tr A I . . . M . E .
, 1 9 1 4 , X LIX , 52 5 .
 S M ELTI NG LE AD ORE S I N TH E BLA S T F URN A CE
’

T AB LE 4 5 — GonrR E v FU RN ACE

Hearth , di a mt e er, ft .
,
in
Hearth ,
revol . in mi n
Blade
s , no and si ze.

Ore, matte

Thi ckness of bed , i n

RO AS TE D ORE
Loss i n wei ght , p er cent 2

Sulp hi de S , sulp hate S, p er cent - -

T otal —
8 10
FLUE -
D U ST :

G AS E S
Cubi c feet p er mi n °
(3 76 C ) .

Per cent . $02, SO ;

FUE L :
Bi tu i nous m coal

A mount per ton rawore , p er cent

LAB O R BE R SH IFT :

Power, h p .

( 1 ) I ncl udes dust fro m H H po ts ( 2 ) See H H p ot s ( 3 ) Feed and di scharge blades ( 4 )

. . . . . . .

Rabbl i ng blades ( 5) Ra wm att e si li ci ous sul phi de gal ena sli m

. e ( 6) Si 02 6 Fe 3 0 02 0 S 2 2 Zn 8 . . . . . . , ,

Pb 2 1 Cu 5 .( 7 ) Matt e S i l i ca : Pb 1 4 Cu
. Si 02 Zn S Fe 011 0
, Ore Pb . .

Cu 8 10: Zn S Fe 02 0 ( 8) Pb Cu Si O z Zn S Fe

E l Paso, Tex ; Trai l , B C ; .

1
. .
1
and o ther work s .
1 “
McNab states that at Trail
the charges u sed to co ntai n Pb CaO 7 Zn < —
Fe 1 0 1 3, Si 02 8 1 1
— —1 0
, ,

1 0 S 1 4 1 7 p er ce nt ; also that charge s w

,
— i th Pb > 4 s per ce nt di d not wo rk . .

well Th e furnaces ran slowly at the rate of 1 rev i n 3 m

. i n halved the ,
. .

S co ntent and put through i n 2 4 hr from 38 to 4 5 to ns charge

-

,
. .

1 Vail , E ng . Mi n . J 1 9 1 4 , X CVIII , 4 65 .

E ast er, Tr A I . . . M E . .
,
1 91 5, LI I , 71 6 .

1
M cN ab J , . Can . Mi n . I nst , 1 909 , X II , 4 2 4 ; Can . Mi n J . 1 909 , XXX , 4 38 , 4 9 8 ; Mi n.

World , 1 909 , XXX I , 5 1

1 .

1 Hofman , Tr A I . . . M . E .
, 1 9 1 0, X LI , 739 .

1
Loc . ci t.
1 70 ME TALLURG Y OF LE AD

H olthofi
hi s i s another form of Brunton furnace cons tructed
Furnace L— T
9 .
1 .

by H C H ol tho ff and bui lt by the Cudahy Power and Mi ni ng Machi nery

. .

Co of Cudahy Wi s It was introduced at the wo rks of the Sai nt Joseph

.
,
.

Lead Co H e rculane um Mo i n 1 907 and has been i n operati o n si nce that

.
, , .
, ,

ti me for the rough ro asti ng of matte In 1 9 1 3 heati ng from the central gas .
,

pro ducer was replaced by oil firi ng wi th modi fied H auck burners whi ch are -

i ntro duced through th e gas po rts the roof of th e produ cer havi ng bee n re -

moved The oi l in use i s Kansas asphaltum base oil of 2 5 2 6 R6 The furnace

.
- -
.

i s shown i n Fi g 1 38 The annu lar roasti ng hearth a 36 ft i n di am. ete r travels .

, ,
.
,

at th e rate of 1 rev i n 1 1 mi n on 2 0 case hardene d roll ers b nea r th e ci r cum . .

-

, ,

fe rence and 1 4 marked c near the mi ddle around the central Taylor gas p ro
, , ,
-

FIG . 1 38 — H olthofi urnace

. f .

ducer, d, 1 1 ft i nne r di amete r provi ded wi th a No 3 Sturt

ft .
3 i n oute r and.
9 .
,
.

evant b lower . The hearth , 9 ft

wi de has a sand seal e to prevent th e entrance .
,
-

, ,

of cold ai r I t carri e s on the lowe r si de near the ci rcumfere nce a ci rcular rack
.

dri ven by pi ni on f ; the shaft of the latte r carri es cog wheel g me sh i ng wi th

,
-

, ,

pi ni o n wheel h who se shaft carri es gear wheel l meshi ng wi th pini o n j on the

-

, ,
- ‘

, ,

mai n dri vi ng shaft ; thi s recei ves i ts power th rough pulley h connected wi th a , ,

6 h moto r T h e sha ft of wh ee ls h and i carri e s also pu lley mwhi ch i s belted

3 p
-
. . .
, , , ,

to the shaft of screw feed n The roof i s supported on the i nner si de by the -

,
.

bri ckwo rk of p ro duce r d whi ch also fo rms one si de wall of the roasti ng ch amber , ,
-

and on the oute r side by wall a carri e d by cast i ro n co lumns p and bou nd by , ,
-

, ,

two 1 by 5 i n steel bands and a i n steel cable to re si st the thru st of the

-
.
-
.

arch Through the roof pass a numbe r of tile pi pes q ending i n mai n flue r
.
-

, , , ,

1
Anon, E ng M i n J 1 905 LXX IX 538 ; M i n Reporter
. . .
, , ,
.
,
1 905, L1 , 6
3 ; El ectroche m Metall.

I nd , 1 90 5 1 11 , 86 ; M etal l urgi e 1 90 5 II 2 9 7
.
, , , ,
.

Pul si fer M i n E ng World 1 9 1 3 XXX IX 1 054

, . .
, , , .

Edi tor E ng M i n J 1 9 1 4 , XCVI I I , 900

, . . .
,
.
1 72 ME TALLURGY OF LE AD

FI G S . 1 39 and 1 4 0 .
— W edge furnace for lead ore and lead matt
e .
 S MELTI NG LE AD ORE S I N TH E BLAS T F URN A CE

eas t
-
i ro n rabble arms whi ch carry cast i ron plow
-
shaped teeth e that are dragged - -

, ,

over the h ear th and by thei r we i gh t penetrate the ore The dryi ng hearth has .
-

two rabb le arms f provi ded wi th plows g whi ch are ri gi dly connected and do
-

, , , ,

no t dr ag over th e hea rth but are lowere d whe n wo rn They transfer the ore fed
, .

at th e peri p hery toward th e center H ere the arms f carry two or mo re feed .
, ,

plates 11 whi ch regulate th e amount of ore that i s to ente r the furnace over a
, ,

ci rcul ar sta ti o nary pla te ; the ore form s a seal whi ch p revents the escape of

gases Th e traveli ng and stati onary feed plates can be rai sed and lowered to
.
-

regulate the feed and to correct th e wear of the i ro n .

The ai r cooled central shaft i of steel plate i s prote cted from heat and gase s
-

, ,

by to ngu ed and grooved fire b ri ck ti les j I t i s 5 ft i n diameter whi ch i s large -

,
. .
,

enough to all ow a man to enter and make seve rally conne cti ons through cast
stee l bree ch lo ck s k wi th th e ai r or water coo led rabb le arm s d of th e ro asti ng
-

, ,
- -

, ,

h ea r t h s The arm s have central parti ti ons tha t th e ai r or water m

. ay flow out

on one si de and return on the other The sh aft i s carri ed by m aster ge ar l .

-

, ,

cente red by p i n m and provi ded wi th a race w ,

ay r unni ng on rollers wh i ch
,
-

are suppo rted by pe destals I t i s rotated through the master gear by .

-

bevel p i ni on q and geari ng r conne cted wi th pulley s of the dri vi ng shaft

, , , , , ,
-
.

Th e top of the shaft carri es steel p an t whi ch fur ni shes the coo li ng water to the , ,
-

rabbl e arm s through separ ate pi pes u ; the hea ted w

-
ater f rom the rabble ar m s ,
-

i s collected i n a cem e nt p an 2 i n the foundati on , ,

.

The two features whi ch di sti ngui sh thi s fu rnace from the pyri te b urner are
two a uxi li ary fireplaces on the ground floor ( not shown) wi th combusti on gas - -

i nlets 10 leadi ng to hear ths 5 6 and 7 ( one o nly shown) and dam
, , p ere d gas , , ,

outlets on hearths 1 2 3 and 4 The mai n object of havi ng the fireplaces has
, , ,
.

been noted above I t will be seen below that these fireplaces are u sed as a
.

ru le o nly i n start i ng a fu rnace and i n m aki ng change s from one class of ore to

ano t h er wh e n the ore fee d i s stopped for a whi le i n or de r to allow th e hearth s to

,
-

clear th em selves and permi t m ak i ng the desi re d cut off I n do i ng thi s the -
.
,

tempera ture of the fu rnace drop s and has to be re stored by ca rbo naceou s fuel .

Some o res whi ch do not gene rate enough heat to roast of thei r ow n acco rd wh en

ki ndled m ay requi re ex traneo u s heat for sa ti sfacto ry oxi da ti o n .

Th e i n tro ducti on of dam p ered out lets x ha d m ad e i t po ssi b le to co ntro l , ,

closely the temperature s on the upper h ear th s on whi ch mo st of th e h ea t i s

developed i n roasti ng and thus to perm i t roasti ng sulphi des of lowmelti ng

,

poi nts I n the ordi nary McDougall or Wedge pyri te burner the gases as
.

ce nd i n the furnace i n a zi g zag p ath of a di recti o n opp osi te th at of the ore -

If .

now asi s th e case here on h earths 1 4 there i s adde d a verti cal gas flue co nne cte d
—
, ,

by fo ur damp ered ho ri zontal passages 90 wi th th e fo ur hearths any ex ce ss heat , , ,

ge nerated on the se hearths can be bled off by pulli ng out the ti les y and thu s , ,

the temper atu re regulated at wi ll A sli gh t change i n the posi ti o n of the .

til es y will show a correspondi ng ri se or fall i n the temp erature measureme nts
, ,

of th e h earth s .

T h e fu rnace w as i ntro du ced i n 1 9 1 1 at the i nstance of A L D wi gh t at th e . .

work s of the Saint Joseph Lead Co H erculaneum Mo for th e rough roasti ng .

, ,
.
,
 1 74 ME TALLURGY OF LE AD

m
of mat te . The res ul ts were so favorable that so n o other smel teri es followed
the exa m e .

The metal parts of a furnace 2 2 ft 6 i n i n di ame ter wei gh about lb . . .

and co st w i th the shaft i nsula ti on $9500 The lev el bri ck arche

-
s req ui re .

about bri cks ( 9 if the hearths are leveled wi th concrete or other

i nert material the number of bri ck i s reduced to about 4 , the si de walls -

requi re abo ut bri ck The co st of erecti o n i s about $1 500 . .

The fur nace m ay be started i n a manner si m i lar to that of the M cD o ugall .

wi th the excep ti on that on account of the draggi ng rabble plows crushed lim e -

stone i s not fed at first to fo rm a worki ng bottom A wood fire i s s tarted .

on hearth s 3 and 5 and kept goi ng wi th a newfur nace for from 3 to 4 days , ,

i n order to bri ng the bri ckwo rk to a dark red Wood i s frequently rep laced .

by an oi l flame Usually however the furnace i s heated up from the fire

-
.
, ,

places Ou the ground floor .

The ore i s nowfed I ts compo si ti on ranges from pyri te through mi xed lead
.

sulphi de ore to gale na co nce ntrate and matte The manner of op erati ng .

therefo re mu st show great di versi ty The work do ne i s best illustrated by ci t .

i ng a few examples ; from these i t will be po ssi ble to arri ve at a few g eneral
stateme nts .

Plant A The furnace i s 2 2 ft 7 i n i n di ameter and the shell 2 1 ft 334 i n

.
-
. .
, . .

hi gh ; i t requ i res 4 % h p the shaft m aki ng 1 7 r p h . . The gas flues on h ea r ths 1

,
. . .

and 2 are Ope n for sq ft The combusti on flue on h ea r th 5 i s open for

. . sq .

ft Three si de doo rs on hearth 7 are open the rest are clo sed The tempera
.
-

, .

°
ture on hearth 4 i s 900 C on h ear th 7 about On hear ths 1 2 and 3
.
, , ,

th er e i s a gas pressure of 0 5 and in water ; thi s changes on hearths

.
, .

4 5
, 6 a
,
n d 7 to a, depre s s i on of a n d i n w a ter T h e ore i s . .

an i ro n su lphi de in w i th Slo g Fe 3 2 CaO 1 Zn 3 Pb I S 3 7 p er cent

.
, , , , , .

The thi ck ness of bed i s 5 to 7 ln th e durati o n of roast about 6 hr The lo ss .

, .

i n we i ght i s about 1 8 per cent wi th a reducti on of S co ntent of about 1 8 per .

-

ce nt There i s made about 2 p er cent flue du st

. The furnace trea ts i n 2 4 hr .
-
. .

5 0 to ns of ore re du c i ng the S c o nte n t to 1 0 p e r cen t T h ere ar e requ i r

-
e d 4 2 lb . .

good grade bi tumi nous slack per ton of ore and th ree men in 2 4 hr ex cl udi ng
-
.
, .

wh eelers for rawand roasted ore .

Plant B — The fu rnace i s 2 2 ft 6 i n i n di ameter and 2 5 ft 916 i n hi gh r equi res

. . . . .
,

3 1 5 h p th e s h
. aft m
. a,
k i n g 2 8 r p h T h e g as flue on he a r th 1 i s ope n f o r . . .

sq ft . that on hearth 2 for

.
,
sq ft those on hearths 3 and 4 are clo sed The . .
, .

combu sti on fl ues are clo sed The side doors on h earth s 1 2 and 3 are cl osed .
-

, , ,

that on hearth 4 i s open 6 i n those on hearths 5 and 6 are closed that on h earth .
, ,

7 i s h alf ope n Th e -
dr a ft o n he a rt h.s 1 7 i nc rea se s from top to bottom ; he a rth -

1 shows i n water ; hear th 2 .i n ; hearth 3 i n hearth 4 . .

hearth 5 hearth 6 hearth 7 Oxi dati on i s vi si ble on

hearth 2 and di sappears on hearth 5 ,
The ore i s a m ix ture of cru de ( 4 mesh) .
-

—
and co ncentrate d ( 2 0 mesh) i ron sulphi de w i th I nsol Fe Cu .

Pb S p er ce n t T h e th i ck n es s of bed i s a bo
. u t 4 i n dur a ti o n of .

roast about 4 hr ; lo ss i n wei gh t per cent S co ntent i n roasted ore

. .
-
1 76 ME TALLURC Y OF LE AD

Zn Cu Pb S p e r ce nt A g a n d A u o z .
,
. .

p e r t on ; th i c kn e ss of bed 2 —
5 3 i n ; du rat i o n of ro as t 6 hr ; l
. o s s i n we i g h t 1 2 5
. . .

p e r ce n t .
; ro a s ted ore co ntai ns 1 2 5 p er cent sulphi de and p er c e n t s u l p.h a te . .

S. Flue dust forme d i s

-

p er ce nt w i th Pb an d Cu p e r c en t . .
,

Ag and Au oz p er t on There pass th rough th e furnace p er mi n ute

. .

cu ft gas at 4 71
°
. C ; flue gas contai ns
.
p er ce nt v o.l 8 0 2 a nd . .

8037 . Fu rnace treats i n 2 4 hr 90 tons ore wi th 2 7 per cent S reduci ng thi s to . .

,

1 1 per ce nt ; wi th matte th e dai ly roasti ng powe r i s

.
75 to ns ; a tte n d a nc e 2 m e n

p er s h if t .

The ore deli vered from th e furnace drop s i nto a verti cal cyli nder placed
above a revolvi ng hori z ontal t able and i s moi ste ne d wi th wate r th us avoi di n g , ,

the formati on of dust From th e table the moi ste ne d ore i s mechani cally
.

raked i nto a car .

P lant F 1 — The furnace 2 1 ft 6 i n i n di amete r and 2 3 ft 5 i n hi gh rough

. .
, .
. .
,

roasts i n 2 4 hr 75 80 tons lead coppe r matte crushed through 4 mesh scree n

—
.
-

,
-

wi thout any ex traneous fuel ; reduces the S content from 2 2 to 5 p er cen t ; -

.

makes less than 8 p er cent flue dust ; requi res 8 gal cooli ng wate r per m . in -
.
-
.

cu ft gas pass ofl per m

°
ente ri ng at 4 and leavi ng at 2 1 C About
'

in . . . .

Draft i s small : depre ssi on i n mai n flue i n wate r; on hearth s 1 and 2 i t i s .

i n ; on hearth 3
. i n ; on hea rths 4 and 5 i t i s scarcely measurab le . .

S um mary From the records of si x plants i t i s seen that the manner of

— .

operati ng vari es wi th the character of the ore The leadi ng factor i s the prope r .

cont rol of tem e rature ; the tempe rature must be lowwi th leady sulphi de s and
p
°
does not exceed 700 C on the thi rd or fo urth hea rth If i t becomes too hi gh
. .
,

the l eady mate ri als soften and adh e re to the h earths from whi ch they have to be ,

removed by barri ng as was the case i n th e mechani cal reverberatory furnaces

,

whi ch di d not pe rmi t a sati sfactory adjustment of heat Thi s control i s obtai ned .

mai nly by the correct admi ssi on of ai r by openi ng the gas flues and by the revo , ,

l uti ons of the mai n shaft The ai r nece ssary for oxi dati on i s admi tted on th e
.

bottom hearth to some extent also on the next follo wi ng Wi th ore only th e
,
-
.
,

fl h e th d re ope ned ; i n some cases the gase s are bled ofl by

'

g as u e s o n a r s 1 an 2 a

havi ng the top flue wi de open the seco nd two th i rds and the thi rd one hal f ,
-

,
-
.

Wi th matte where the re i s much danger of fri tti ng ; all the gas flues are opene d
,

somewhat and thi s to a grea ter ex tent than wi th ore

,
In h eati ng the fu rnace .
,

flame m ay be admi tted th rough th e three combusti on i nl ets w ; u su a lly h oweve r ,

i t enters the fifth or si x th h ea rth The number of revol uti ons of the shaft i s .

smaller wi th matte than wi th ore The draft on the hearths i s often so weak .

that i t i s di fli cult to make a measurement ; i n the mai n flue the depressi on ranges
from to i n water The dryi ng hearth on top of the furnace remove s only
. .

from 6 to 7 p er cent water from a concentrate on account of the lowtemperature

.

at whi ch the roast i s carri ed on The fir st roasti ng hearth dri ves off the remai n .

i ng water and heats the ore so tha t i t can ki ndle on the se cond ; the temperature
reache s a maxi mumon the thi rd and i n some cases on the fourth h earth and ,

then decreases The tonnage range s from 60 and 90 tons sulphi de concentrate
.

1
See also Anderson, E ng . Mi n . J 1 9 1 4 , x cv m5 ,
1 .
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN ACE

( 8103 5
—
1 8, — Pb
Fe 1 6 1 8, 4 S p e rZn 7
c e n t ) w i th -

1 2 per c
1 0,e n t : S —
20 2 ,
—
2 7 30 .

i n roa sted ore to 75 tons matte ( Pb 1 5 Cu m Fe 5 1 S 2 2 per cent ) wi th 1 2

, , , ,
.

p er c e n t S i n ro a
. s te d m a tte If c o n c e n t ra te s co nta i n more th a n 2 8 per
. c e n t S .

i t i s advi sable to di l ute th em wi th other mate ri al so that the S content m ay not -

exceed thi s figure The thi ckness of bed vari es from 3 to 7 i n and i s li kely
. .
,

to be nearer 3 than 7 The amount of flue dust formed vari es from 2 to 5 per .
-

ce nt .
3, b e i n g a fa i r ave ra ge T h e g a s e s i ss ue from t h e fur n a c e w i th a
. t e m
°
p e ra t u re v a ry i ng f rom 2 2 5 to 3 00 C ; th ey c a rry about 3p e r ce n t v o l SO ; a n d . . .

o nly a li ttl e 803 The fuel ne cessary i s li ttle ; the labor requi red depend s upon
.

the numbe r of furnace s and the local arrangeme nts for handli ng materi al s ;

the po we r vari e s from 3 to 5 h p . .

A study of the work done by th e di fferent forms of McDougall furnace s 1

will show the changes i n mode of operati ng necessary for treati ng materi als
t hat are readily fusi ble .

93 H u. n ti n g to n H eb er le i n P roc e ss 1 T hi-
s pro c e ss i n i ts or i gi n a l form ( 5 8 4) .

comp ri s e s five operati ons : p repari ng of cru she d ore mix i ng of sulphi de lead ore ,

and li mestone rough roasti ng i n a reverberatory fu rnace moi ste ni ng rough

, ,

ro as ted m i xture forci ng ai r th rough i t i n a pot and di schargi ng blast roaste d

, ,

ch arge .

T h e process ori gi nally i ntended for a galena concent rate has been ch anged
Thu s the presence of li m
.

in ma ny i nstances to meet newcondi ti o ns estone .

,

havi ng bee n found not to be essenti al i ts addi ti on has bee n di spe nsed w i th , ,

and s tress lai d mai nly upon the ch emi cal compo si ti o n and the phy si cal con

di ti o n of the charge The mi x tures at p re se nt are made up of o xi di ze fine s

.
,

si li ci o us sulphi de s conce ntrate s sli m es and rough roasted hi gh S ore s; flue

, , ,
- -

dus t appea rs to i nte rfe re to some ex tent wi th the process

1 1
Facts regardi ng .

these poi nts are contai ned i n Table 4 6 .

R ough roasti ng of mi xtures freque ntly p repare d by bed di ng the com ,

— wo k of dfrey fur e
p o n e n ts h a s bee
,
n d i scu s sed i n § 88 9 2 T h e r t h e G o n a c .

meri ts spe ci al attenti on be cause thi s furnace as well as i ts counterpart the , ,

H un ti ngton H ebe rlei n w as fo rme rly use d e xcl usi ve ly for rough ro asti ng
-

,
.

Th e us ual w ayof addi ng th e water ne cessary for moi steni ng the rough roasted

mi xture i s to have a spray of water i ssui ng from a horiz ontal pi pe wi th num ,

erous pe rfo rati ons on the lower si de sp ri nk le the ore as i t drops f rom the furnace ,

into t he recei vi ng bi n from whi ch i t i s transferred ei th er i nto cars or by means

,

of a co nveyor or elevator i nto the feed hoppers of a battery of blo w i ng pots ; - -

it m ay however go first i nto a bri ck storage bi n whi ch serve s the b atte ry -

.

.
—
Fi gs 1 33 1 3 7 show such an arrangement .

Th e cast i ron pots o ri gi nally used by H unti ngto n and H eberlei n were co ni cal,
-

earri ed detachable hoo ds and h e ld a li ttle over a ton of ch arge ; they were ,

1 H ofman gy of COpp er ,
“M etall ur
, 1 9 1 8, 9 1 .

1 H untington Heberlei n E ng Mi n -

, . . J 1 906, LXXX I , 1 00 5 ; German Patent N o 9 560 1 ,

.

1 89 7 ; U S Pat ent N o 60034 7,

. . . March 8, 1 898 .

1
Pal mer ,
Tr A I
. . . M . E .
, 1 9 1 4 , X LIX , 5 1
1 .

1 Norton , Ri dell, D wi ght , lac . ci t .

, p 4 8 5 a
.nd foll .

12
1 78 ME TALLURG Y OF LE AD

mounted trucks and trundled to the reve rberatory furnaces to recei ve thei r
on

charges The si ze of pot w

. as soon doubled and the n furthe r i ncreased to ho ld ,

charges of 8 to ns at Port Pi ri e N S W and 1 0 to ns at Tarnowi tz Si l esi a

1 1
.
, .
, , ,

Chillagoa Queensland and oth er locali ti es

1
,
The large si ze pots were mounted .
-

on t runni ons and ti pped by wo rm and hand wheel ; the hoods were fixed i n the -

buildi ng .

In the Uni ted States the pots are alw ays of cast i ro n and have a capaci ty of

from 8 to 1 2 tons charge ; th ey are close on to 9 ft i nner di ameter and 4 ft 8 in . . .

deep In the o lder plants and i n small works the pots are mounted on trunni ons
.

9 ft an.d more above th e floor an d dumped w i th wo rm and hand w he el ,

-
.

DETAIL AT J O INT SHOWING 1 00

FOR HO LDING PERFORATED BOTTON
5

Di e m
.

1 10
1 441
FIG S . 141 to 1 44 .
— Sect i o nal cast -
i ron pot for blast roast i ng .

In moder n la rge
melteri e s they rest on pi e rs ei ther on the furnace floo r or
-
si ze s

i n a p i t and are mani pu lated by means of an ove rhe ad crane

, O ri gi nally .

the pots w ere si ngle casti ngs ; they cracked frequently owi ng to th e severe
thermal and me chani cal strai ns to whi ch they are subjected At present pots .

are cast i n flanged secti o ns the bottom and four si de secti o ns are bo lte d to ,
-

gether and the joi nts are made ti ght wi th asbestos packi ng Such a po t i s
,
.

shown i n Fi gs 1 4 1 1 44 whi ch requi re no comme nt

.
-
The b last i nl et pi p e f ro m
,
.
-

43 6 to 6 i n i n di amete r e n
.te ri ng tange nti ally at t h e bottom d e li
,
ve rs p r e ssu re

ai r be neath a ci rcular cast i ro n p lat e 6 to 8 ft i n di amete r w i th 2 00 j : holes

-

, .
,

1
Delp rat , Tr Ansl r I nsti t M i n E ng , 1 90 7, XII , 1
. . . . .

1
m
Bi rnbau , Z t Berg H atten S al W i Pr , 1 905,
. . . . . . . L111 , 2 1 9 ; E ng
. Mi n J . .
, 1 90 5, LXXX,

53 5.
6 8°
1
Wi lli ams , E ng . Mi n . J .
,
1 909 , LXXXVII , 603 .
1 80 M E TALLURC Y OF LE AD

to 94 i n i n diameter The plate usually called grate was at firs t ca st i n

. .
, ,

one pi ece ; at p resent i t i s made up of from 4 to 6 rabbeted secto ral pi e ces whi ch

are supported at the center by a col umn about 1 8 i n hi gh . .

Tw o e xamples m ay serve to show the general arrangeme nt and the detai ls of

a modern H unti ngto n H ebe rlei n plant -

.

1 H unti ngton H eberlei n Plant -

with Godfrey Furnaces and Pats Ti tl ed by
Warmand H and wheel -
.
— Th i s is sho w
—
n i n Fi gs 1 4 5 1 4 7 . . Fi g 1 4 5 gi ves the
.

gene ral plan The roasti ng di vi si on has five Godfrey furnaces N os 5 2 9 ft

. , . 1
—
,
.

4 i n oute r.d i ameter p la c e d a t 3 8 ft ce n ters ; t he b las t ro as ti n g dep artme n t ,

-
.
-

has 1 0 H 81 H pots N os 1 1 0 8 ft 836 i n i n di ameter placed at 1 5 ft ce nters ;

— . .
,
.
, . .
,
-
.

between th e two hes the machi nery se cti on Th e total length of plant is 2 2 8 + .

ft and the wi dth 1 00 ft .

,
.

The ore arri ves from the ore beds i n Truax cars ( Fi g 1 4 6) on track a Fi g -
.
, , .

1 4 5 i s r ai se d by hy drau li c p lunge r e levato r b ( run 33 ft ; speed 60 ft per m in ; , ,

.
. . .

l oad 500 lb ) and moved over track c to be di scha rged i nto fee d hoppers d of
,
.
, ,
-

, ,

the Go dfrey fu rnaces To th e ri gh t of each of the se are the fire p laces e Th e .

, .

gases pass off th rough gab le shaped pi pe flues f i nto m ai n flue and dust -

, ,

chambe r g leadi ng to chi m ney h ,

The rough roasted ore i s di sch arged i nto bi ns
, ,
.
-

i empti ed from bottoms and si des i nto ore cars runni ng on t racks j and j to
'
-

, , ,

hy drau li c e levato r b whi ch rai ses the materi al to th e level of overh ead track 11 , , , ,

—
from whi ch i t i s fed i nto blast roasti ng pots 1 1 0 The gases fro m the pots p as .

at the back th rough gab le shaped necks i nto mai n flue g Th e blast roasted -

,
.

cakes are dumped at the fro nt on to platfo rm n wh e re th ey f all upo n b lo ck , , ,

y ,
Fi g 1 4 7 a n d are furt
. h er b roke n by h an d a,
nd th e l ump s t h e n l o ade d i n to ,

stee l cars a on su nken track p , , ,

.

The machi nery di vi si o n has a 50 h p motor to dri ve a No 6 Co nnersvi lle -

. . .

blower furni shi ng blast to the pots ; a 1 5 h p motor to dri ve a 536 by 8 ih -

. .
-
.

'
tri ple Gould pump to provi de pressure water to tank b 4 ft i n di amete r and -

, ,
.

1 2 ft long and a 2 0 h p motor dri ve th rough pulley 76 i n i n di amete r li ne

.
,
-
. .
, .
,

shaft g 2 366 i n i n di amete r m aki ng 1 50

, , whi ch i s connected by t rans
.
,

mi ssi on r wi th th e five Godfrey furnaces Fi g 1 4 6 gi ves the ve rti cal secti on

, ,
. .
,

AB of Fi g 1 4 5 through the fireplace of a Godfrey furnace and gi ves detai ls of

, .
,

the latter These have been touche d upon above and are cl ear from thedis
.
,

cussi ons gi ve n i n conne cti on wi th Fi gs 1 33 1 37

—
It m ay be ad ded t hat th e . . .

gases from f urnaces Nos 2 3, and 5 pass through hori zontal flue 2 i nto mai n .
, , ,

flue g whil e those from furnaces N os 1 and 4 travel th ro ugh gable sh aped
, , .
-

flue f , .

Fi g 1 4 7 gi ves the verti cal secti o n CD of Fi g 1 4 5 through an H 81 H

.
, ,
. . .

pot T he pot 8 ft 836 i n i n di amete r i s suspended below i ts center of gravi ty

.
, . .
,

by trunni o ns I t i s ti lte d i n a verti cal plane from the worki ng platform by means
.
-

of worm gear s whi ch consi sts of an endless screw wi th hand wheel and a sp i
-

, ,
-

rally toothed whee l The pot has a secti onal grate t beneath whi ch e nters the .
, ,

6 i n b last i nlet connected by means of a rubber hose wi th the blast m

-
.
-

ai n The -
.

space beneath the g rate has a clean out doo r so The pot i s covered wi th sh eet -

, .

i ro n hood It provi ded wi th feed ope ni ng a to recei ve the charge and wi th doors
, ,
-

, , , ,
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN A CE

w for watchi ng the progress of

, a blow and for poki ng down blow holes th at -

are li k ely to form .

2 . H unti ngton H eberlei n Plant -

Mani pulated wi th Godfrey Furnaces and Pots
by E lectri c Crane — Fi g 1 4 8 gi ves a cro ss secti on showi ng the leadi ng fea tures
.
-
.

Ore and coal arri ve on 1 6 i nch belt conveyor a whi ch deli vers i nto bi ns (ore bi ns - -

, ,
-

b o nly are show

, n) whence the materi als are dr aw n i nto ca rs to be di scharged
i nto Godfrey furnace c or coal bi ns d whi ch serve th e fireplaces The power , ,
-

, ,
.

necessary for dri vi ng the machi ne ry i s deri ved from mai n shaft e and transmi t , ,

ted t hrough belti ng to the conveyor and the Godfrey furnaces From these the .

FI G . 1 48 — . Hunti ngton Heberlei n -

p lant wi th Godfrey furnaces and p o ts mni p ulat

a ed by
electri c crane .

ashes are hauled away i n cars f; the gases pass 03 th rough pi pes g i nto b alloon , , ,

flue h ; t he rough roasted ore i s di scharged i nto cars i whi ch deli ver th ei rco nte nts
,
-

, ,

to po ts i A se ri es of 1 5 ton pots one to three roasters i s p laced i n a p i t served

,
.
-

, ,

from an overhead 2 0 ton electri c crane The pots 8 ft 8 i n i n di ameter and-

.
,
. .

4 ft 5 36 i n
. deep are m ad e up of 4 s
.i de pi e ces an
,
d one bottom p i e ce ; th ey re st - -

on fl oor b lock s The movable hoods k are balanced and deli ver th e gases
-
.
, ,

thro ugh teles cope joi nts to stati onary pi p es endi ng i n balloon flue h A pot i s -

, .

charge d from a platfo rm and t ransfe rre d to i ts place the hoo d i s lowere d and , ,

blo wi ng starte d After a blow the hood i s rai sed the p o t li fted by the ele ct ri c
.
, , ,

crane transfe rred to one end of th e bui ldi ng and there by means of hook and
, , ,

chai n overturned from i t s elevate d posi ti o n to di scharge the cake w

,
hi ch falls ,

upon a pla tform of rai ls or I beam s Frequently the fines lyi ng on the top of -
.

the cake are poured 03 i n a separate place w hile the p ot travels from p i t to
d umpi ng platform The large r pi eces of blast roasted cake are p i cked up by
-
.
1 82 ME TALLURG Y OF LEAD

the crane and dropped agai n; the sm aller are li fted by hand or shoveled i nto E

Blake crusher whi ch redu ces them to the proper si ze for the blast furnace .

The mode of operati ng a pot vari es as regards detai l i n di fi erent plants but ,

i s practi call y the same i n i ts ge neral fea tures .

For the protecti on of the grate some works give a layer of 2 or 3 i n of .

ashes crushed sili ci ous ore or li mestone b efore they i nt roduce the k i nd li ng;
, ,

others begi n wi th ki ndli ng It used to be more common than i t i s at present .

to spread a barrow load of ash es in a thi n layer and follow thi s wi th a charge of
-

hot calci nes whi ch se rved as ki ndli ng Instead of ashes ca lca reous or .
,

si li ci ous ore free from Pb i s freque ntly gi ven at fi rst Wi th charges lowi n Pb .

or charges whi ch do not si nter readi ly the use of hot calci nes forms a qui ck and
effi ci e nt method of starti ng Wi th hi gh lead charges there i s danger of th e .
-

bottom of the charge si nteri ng and th us obstructing the passage of the blas t .

Therefo re hot calci nes are not used i n such cases but half burnt coal f rom t he ,
-

Godfrey furnaces Wood serves as ki ndli ng where hot coals are not available
. .

At E l P aso Tex two Godfrey furnaces are fired wi th oil and one wi th coal i n
,
1
.
, ,

order to furni sh the i gni ti on fuel for the pots The mai n consi derati on i s to .

bri ng the charge to the ki ndli ng temperature wi thout causi ng i t to cake .

Wi th the ki ndli ng bur ni ng i n place and the blast started from 1 to 2 tons ,

ore charge i s gi ve n and the b last roast started w

-
i th blast pressure of from 1 to
,

2 oz per sq i n
. When thi s i s under way the rest of the charge from 8
. .
‘

, ,

to 9 tons i s i ntroduced and the blast pressure rai sed from 4 to 6 oz at a time
, , , .
,

until the maxi mum of 1 2 or 1 4 oz i s reached Tow ard the end of a blow th e . .

pressure i s generally lowered i n order to prevent an excessi ve loss by dusti ng .

When a charge has been i gni ted the oxi dati on wi th the sintering p ro ,

gros ses upward The si nteri ng i s probably ca used by the uni on of 8103 and
.

PbO w i th other compo nents such as CaO and F00 perhaps also of CaO ,
° °
and Fe, O ,
1
The tempe rature at tai ned reaches 1 000 and 1 2 00 C and falls
.
1
.
,

03 qui ckly when oxi dati o n and si nteri ng cease Thus the si ntered charge .

benea th the ri si ng zone of oxi dati o n cools and doe s thi s qui ckly owi ng to the ,

blast passi ng through i t .

The gases from the pots contai n li ttl e S03 ; the volume of gas set free at
first i s small i ncrease s gradually and finall y falls ofi qui ckly
, I t has alway s , .

bee n held that the SO: could not be uti li zed i n the manufacture of
Accordi ng to Wi slecenus SO , i s converted i nto 80. by the contact pro cess at
1

a German plant the pots bei ng run i n consecu ti ve ord er to furni sh a uni form
,

percentage of
When a charge has been blown ei th er the pot wi th cake and fines i s dumped ,

on to a bri ck pavement beneath a battery of pots as i n Fi g 1 4 7 whereupon the , .

,

1
Vail ,
E ng . Mi n . J .
, 1 9 1 4 , XCVIII , 4 65 .

Easter, Tr A I 5, . . . M . E .
, 1 91 LI I , 71 6 .

1
Kohhneyer Hilp ert, Metall nrgi e, -
1 9 1 0, VII , 1 94 , 2 2 5 .

Kohlmeyer, lac . ci t .
, p . 2 89 .

1 Hofman Reynolds Wells Tr A I M E 1 907 XXXVIII 1 2 6

- -
,
. . . . .
, , , .

1
Ueber di e Grundlagen techni scher and gesetz li cher Maassnah men gegen Rauchschl den ,

Parey, Berli n, 1 908 , 45

1 84 ME TALLURGY OF LE AD

At the works of the consoli dated Mi ni ng and Smelti ng C0 of Canada .

,

Trail B C whi ch have 38 H 81 H pots a crane deli vers the blown pot to th e
,
. .
, . .
,

breaki ng floor pours ofl the fines and du ps the cake whi ch i s broken by a , , ,

drop wei ght i nto lumps An electri c crane w

-
i th clam shell bucket pi cks up .
-

l ump and fine s and deli vers both to a hori zo ntal bed 1 1 by 8 ft of steel ro lle rs
, , .
, ,

—6 i n i n di ameter and i n centers these screen out the fines whi ch o to the
5 3 ; g
-
. .
,

Dw i gh t Lloyd machi nes and feed the over si ze to a Blake crusher 2 4 by 3 6 i n

-

,
-

, .

The crushed materi al drops i nto cars whi ch are hauled to st orage bi ns of cem e nt -

co ncrete and empti ed ,

.

Detai ls of H unti ngton H eberlei n pots are gi ven i n Tab le 4 6 -

.

Double tre atme nt i s taken up i n § 1 00 -

.

The co st of blast roasti ng of tons or more ore i n a 50 ton plant has been -

esti mated by Austi n The loss i n wei ght was 2 5 per cent ; the gai n i n An
1
. .
,

7 per c e nt ; t he lo ss i n A g per ce nt ; i
. n Pb per cen t ; an d i n Cu p e r ,
.
,
.
,

ce nt .An average analysi s of blast roasted ore gave : Slo g 6 Fe 35 Cu 1 , , ,

Zn Pb 1 5 S per cent and Ag 2 1 oz per ton The cost of blast roasti ng

,
.
,
. . .

was : 1 3 men at per day fo reman (part) fuel for roasti ng , ,

( sla ck c o al) 6 to ns at $ 1 55 powe r ( e sti m a

,
te d) li g h ti n g ( esti ma te d ) .
, ,

repai rs and suppli es (esti mated) total for 43 tons or , ,

per ton .

The co st of roasti ng i n a hand reve rberatory furnace at the same plant w as

per ton ; and of bri quetti ng roasted materi al p e r to n Th e l o ss , .

i n Pb ranged from 1 1 to 1 7 per cent .

Compari ng the two processes gi ves : cost as loss i n Pb , .

,

as 1 1 1 7 per ce nt ; quali ty of p ro du ct for b last furnace good vs passabl e

—
. .
,
. .

Another esti mate of cost i s that of Ingalls whi ch gi ves a hi gher figure
2
.

94 . Other For ms of Up draft Blast Roasti ng Pots and Processes

- — Th e
u
s ccess of the H unti ngton H eberlei n process prompted the constructi on of -

di flerent form s of pots whi ch i n part called for modifica ti ons i n the m ode of
operati ng .

In Fi g 1 4 8 the gases from the pot ascend th rough a ve rti cal telescopi c and
.

the n through an i ncli ned pi pe i nto the balloon flue The telescope pi pe i s .

i n the w ay of the crane ; i t i s qui ckl y corroded as i s the b alloon flue the li fe of ,

th e pi pe averagi ng perhap s only 6 months ; the dri ppi ng moi sture also corrode s
th e hoo d of the pot These di sadvantage s are obvi ated by the Ri chard hood .
,

—
shown i n Fi gs 1 4 9 1 51 H ood 0 whi ch has a larger di ameter than b lowpot
. .
,
-

b re sts i n groove 6 carri ed by bri ck and co ncrete wall d ; the joi nt i s m

, ade gas
, , ,

ti ght by a sand seal From the si de of the hood passes out ho ri zo ntally pi pe -
.
,

6 wi th e lbow whi ch reach es i nto the sand se al placed on top of bri ck chamber
,
- -

f ; from thi s upt ake g car ri e s ofl the gase s to th e b all oo n

,
flue se rvi ng a seri e s of , ,

pots When a charge i s to be introduced or th e b last roasted cake to be

.

di scharged h ood 0 wi th pi pe 0 i s rai se d by means of an electri c traveli ng crane

, , , , ,

and transfe rred to one si de and t hen the pot removed to the dumpi ng platform ,
-
.

1
Mi n . S c Press, . 1 908, X CVI , 64 1 .

Tr A I . . . M . E .
,
1 90 7, x xxvn, 5 8
2 .
 S M ELTI N G LE AD ORE S I N TH E BLAS T F URN ACE

In ome plants the pot wi th i ts blown charge i s first placed by the crane
s on to
p latfo rm scales to asce rtai n the loss in wei ght cause d by blast roasti ng . The

Re mv
o e PI

S ECT IO N ON

VERT ICAL S ECTION

F1 05 . 1 49 to 1 51.
— Ri chard hood
.

Ri ch ard h ood has replaced the u sual fo rm i n seve ral plants , and i s go i ng to do i t
in othe rs .

F . D Baker
.
1
patented a hood whi ch covers the blowi ng pot in manner
1
U S Patent No 94 2 8 1 0, Dec 7,
. . . . 1 809.
1 86 M E TALLURG Y OF LEAD

simi lar to that of Ri chard but the gases set free in blast roasti ng are deflected ,

by the hood pass off between hood and ri mof pot descend outsi de of the latter
, , ,

and ente r a flue conne cted wi th an exhaus t apparatus Doo rs i n the hood .

gi ve acce ss to the charge when the b last has been shut 03 Thi s pot found in .
,

several Colorado plants has th e di sadvanta ge that i t has to be fille d befo re the ,

blast can be turned on and does not permi t co rrecti ng surface condi ti ons of the ,

charge wi thout sh ut ti ng ofl the blast and even th en much smoke passes off i nto ,

the open These pots have therefo re falle n i nto di sfavor

. .

H H aas co ns tructed a pot whi ch w

l
. as i n ope rati o n at To rreo n M exi co ,
.

The essenti al parts are a bo wl shaped cast i ron vesse l 6 by 1 2 ft wi th grate -

,
-

,
.
, ,

holdi ng 1 0 tons of charge supported by trunni ons th rough whi ch enters the ,

blast ; a stati onary hood ( wi th doors) deli ve ri ng the gase s to a balloon shaped -

dust fl ue; a hopp er for holdi ng the prepare d mi xture suppli ed by a belt co nveyor;
- -

a til ti ng devi ce ; and an adjustab le ai r supply Wi th a 400 ton pla nt of 20 -

.
-

uni ts each treati ng t wo charges per day the cost of blast roasti ng i s esti mated at
, ,

68 cts per ton . .

H C B elli nger pate nted a co nti nuous up draft furnace whi ch co nsi sts of a
.
’
.
-

hori zontal traveli ng grate over part of whi ch ex te nds a vaulted roasti ng cham ber ,

co nnected by a pi pe wi th a devi ce for furni shi ng i ndu ced draft . At the fuel .

end of th e grate and outsi de of the roasti ng chamber are two hoppers ; one feeds

the ore m i xture on to the grate to be i gni ted by a burner; the other fee ds on top of
the ore a bed of cru shed li mesto ne coarse ore or other sui table materi al whi ch , , ,

servi ng as a fil ter ho lds b ack the dust created by the power of the i ndu ce d draft
,
.

The si ntered ore i s di scharged out si de of the roasti ng chamber at th e end op

p osi t e th e fee d .

Another apparat us to be menti oned i s that of Vi vi an ’

.

‘—
Robi nso n Roaster box Thi s has been i n operati on at Mi d val e Utah -
.
,
.

The leadi ng parts are a perfo rated cast i ron plate fo rmi ng t he roof of an ai r -

box and th e floor of a lowb ri ck shaft w i th door at th e b ack for adm i t tance of
rack and pi ni o n dr i ve n p ush er and a sli di ng door at th e fro nt for p assage of
-

blast roasted cake A rowof 2 0 furnaces di d the work of the plant at a cost of .

$ 1 2 0 per ton They have bee n replaced by Dw

. i ght Lloyd machi ne s
.
-

F G Kelley used at the Ti nti c sme ltery U tah a ti lti ng tray shaped
.
Ii
.
, ,
-

vessel wi th grate provi ded wi th under grate blast and movable h ood ,
-

, .

Knapp Kunz e blast roasted rawcoppe r beari ng galena i n pots at Z eehan

‘ - -

Tasmani a where the operati on goes by the name of the Knapp Kunze
,
-

pro cess .

McMurtry Rogers di d si mi lar work wi th copper o res and matte at Wallaroo

" -

E ng . Mi n . J .
, 1 9 1 0, x c
,
81 4 .

U S Pat ent N o 94 2 052 , Dec 1 0, 1 9 1 0

. . . . .

U S Patent , N o 9 50 798, M arch 1 , 1 9 1 0

. . . .

Hofman M E , 1 9 1 0 x u 74 7
,
Tr A I . . . . .
, ,
.

Palm er, M bras and M i neral s 1 90 9 1 0 xxx

—
, , , 4 96 .

Hof man Tr A I M E 1 9 1 0 , 74 7 . . . .
, ,
.

Poole, Sydney U ni versi ty Bug g Soc , N ov 1 1 , ’

. . 1 89 8 .

7 —
Cloud, Tr I nst Mi n Met , 1 906 0 7, xvr, 3 1 1
. . . .
188 M E TALLU RGY '
OF LE AD

SO; 8 5, CO, 0 5, CO no ne , 0
. per cent vol In the process fuel i s
. N 80 . .
,

fed and ki ndle d, a ge ntle b last turned on the charge i ntroduced and the hood , ,

lowered The ch arge warm s wate r i s dr i ve n off th e n follows sulph urous gas
.
, , ,

whi ch i s co nducte d i nto a sulph uri c aci d chamber -

.

The re has bee n much spe cula ti on regardi ng the chemi cal reacti ons i n whi ch
thi s proce ss di fi ers from the H unti ngton H eberlei n and Savelsberg proces ses -

trea ted i n and 96 H ofman Mostow i tsch found that th e de composi ti o n

1
.
-

temperatures of CaSO4 by hea t i n the ab sence or presence of Si 03 are hi gh er

than those attained i n blast roasti ng ; Schii tz however has shown that t h e
’
, ,

decompo si ti o n of CaSO. by Si 02 i n the presence of Pbs ( see § 85) begi ns a t

C ; also that the strongly e ndo therm
°
800 C and i s complete at. ic .

reacti on requi res the pre sence of an extraneous source of hea t whi ch i n th e ,

present case i s suppli ed by FeS and ZnS The supposed reacti on PbS + .

=
CaSO4 PbSO 4 + CaS doe s not take place 3
The short ti me requi red fo r .

trea ti ng a charge may be attri buted to the i nti mate m i xture of ore and flux ,

and to the reacti o n of Schii tz .

The co st per ton of ore w i th labor at p er 8 h r gyp s um a t , .

,

per 2 2 4 0 lh and coal at per 2 2 40 lb i s esti mated to be :

.
, 5 t o n .

gypsum dehydrati ng and granulati ng gypsum

, dryi ng charge ,

mi xture co nverti ng
,
breaki ng si ntered cake ton co al , , ,

total Credi ti ng li me i n the si ntered product estimated a t

, ,

reduce s the cost to

From the foregoi ng i t appea rs that i n pri nci p le and practi ce the proce ss
gi ves goo d results provi ded there i s a ch eap supply of gyp sum and a sati sfactory , ,

way for uti li zi ng the large volume of SO, set free ; i ts field i s therefore li mi ted .

The reasons for gi vi ng up the p roce ss i n Australi a were that the sulph urous gas
never gave an SOg content exceedi ng per cent and tha t the S content of -
.
-

the cake averaged per cent ‘

.

9 6 S av
. e l sb e rg P ro cess IS—
T h e le adi ng fea ture of thi s p ro ce s s i s tha t ra w .
L

g a l e n a c o nc e n tr ate m i x ed wi th f rom 1 5 to 2 0 p e r ce nt c ru sh ed li m e sto n e an d .

si li ci ous ore and wette d i s charg ed gr aduall y i nto a pot on to a glowi ng bed of
, ,

fuel and b lown The converter i s bowl shaped and rests upon a truck Th e
,
.
-
.

ori gi nal po ts had a capaci ty of from1 to 2 tons charge but have been i ncreased ,

i n siz e to hold 8 tons .

At Ram sbeck We stphali a the converter i s ft i n di ameter wei ghs , ,

.
.
,

2 860 l h and ho lds an 8 ton charge

.
,
A typ i cal charge consi sts of 1 00 p arts -
.

1
Tr A I M E 1 908 , m m6 28

m
.
. . . .
, , .

Metall urgi e ,
1 91 1 , v ,
2 28 .

Doeltz M etallurgi e, 1 905, 4 60 ; E ng M i n J , 1 906, LXX XI , 1 75, see also 585

,
11 , . . . .

Ri ddell, G C , p ri vate co uni cati on, Sep t 1 3, 1 9 1 6

. . mm . .

U S Patent N o 755598, M arch 2 2 , 1 904 ; er an Patent N o 1 7 1 2 1 5, 1 906

. . . G m .

I ngalls, E ng M i n J , 1 90 5, 1 06 7 . . . .

Savelsberg, M i n Mag 1 90 5 x 11 39 1 . .
, , , .

E di tor E ng M i n J 1 906 Lxxx r 1 1 36 .

m
.
,
. .
, , ,

Hof man Reynolds Wells Tr A I M E 1 90 7, xxx v 1 26

m74 6
-

,
. . . . .
, , .

Hofman , o p . ci t .
,
1 9 1 0, x ,
.
 S M ELTI NG LE AD ORES I N TH E BLAS T F URN A CE

a l na c nc ne o e trate (Pb 1 5 per —

1 0 si li ci ou s si lver ore
60 78, and S
g ,

1 0 spa thi c i ro n ore and 1 9 li me sto ne The mi x ture contai ns therefore about
, .

1 1 p er cent S and 9 per cent Si 02 . Ore and flux are pulveri zed separately . .

i n ro ll er or ball mills to pass a 3 mm screen are bedded and m -

i xed twi ce ; -
.
, ,

befo re the se cond mi xi ng 5 per cent water i s added In starti ng a blow the . .
,

g r a te i s c overed w i th a la yer of c ru sh e d li me s to n e ; th i s i s fo ll owed by a bed of

g low i n g c o al a n d the l a tter ,
c overed w i th li m e sto n e T h e b las t i s s ta rted
‘

.
,

and moi stened charge fed to a depth of about 1 2 i n When the surface has .

become red hot 3 se cond layer of mi xture i s i ntroduce d and the operati o n
, .
,

co nti nued un ti l the co nve rter i s filled Whi le chargi ng about 2 50 cu ft of .

, . .

ai r i s for ced i n per m i nute at a pressure of from 5 to o z per s q i n ; . . .

t h e vol ume i s then i ncreased until the pressure reach es 1 1 5 1 3 5 oz — The . . .

8 ton charge i s b lown i n about 1 8 hr

-
The co nverter i s til ted and th e cake .
,

d umped upon a verti cal i ro n bar; i t i s th us b roken i nto several pi ece s whi ch are
further reduced i n si ze by hand Under favorable condi ti ons the S content .
-

—
o f th e charge i s red uce d to 2 3 per cent ; the loss i n Pb i s sai d to be 1 p er cent . .

and that of Ag ni l .

At H erculaneum Mo the Sai nt Joseph Lead Co had i n operati on 1 8 pots

1
,
.
,
.

placed i n two rows A p ot cast i n one pi ece w . as ft i n di ameter and 4 % , , .

ft deep and had a 5 i n blast i nlet The grate cast i n two pi eces was 3M ft
.
,
-
.
-
.
, , .

i n di ameter and 8 i n above the bottom at cente r; i t had thi rty . i n ho les . .

Th e p ot s were suspended from t runni o ns and tilted by worm gear A charge -

.

'

o f 7 to ns co nsi sti ng of gale na co ncentrate and roasted m atte rangi ng from

,

i n to 2 00 me sh and mi ll tai li ng w
-
.
-
as prepared mechani cally
,
2
deli vered -

, ,

by bel t conveyor to boot of elevator di scharged i nto bin above chargi ng floor
-

,
-

and fed f rom the re by hand to the po ts The followi ng two analyses gi ve the .

co m po si ti on : Si 03 FeO Cao Mgo Pb Zn

S H 20 6 per ce nt ; and Si 02 1 2 FeO 2 0 CaO 9 Pb 4 2 S 1 0 1 2 H 20 .
—
, , , , ,

5 p e r ce n t I n s ta rti n g . glo w i n g c o a l f rom a sep ar a te fi r ep la c e w

,
a s fi r st
put i n the blast turned on and then charge fed gradually unti l the pot was
, ,

fil led The blast pre ssure 1 0 oz at first w

.
-
as rai sed to 2 0 oz and i ncreased
,
.
, .
,

t o 2 5 oz toward the end of the 1 0 hr b low ; the amount of ai r b lo w

. n ranged -
.

from 1 000 to 1 500 cu ft per m i n from 1 5 to 2 0 per cent of the charge . . . .

rem ai ned unsi ntered and had to be ret reated The b last roaste d cake w as .

dum ped and broken by hand ; i ts composi ti on was Si 02 FeO CaO

M gO Pb Zn S per cent The S content of thi s analy si s i s low .
-

th e ave rage i s nearer 3 5 per cent of whi ch per cent i s sulphi de and 0 5
. .
,
. .

su lpha te S The flue dust formed amo unted to about 2 p er cent

-
.
-
O ne m an .

i n a shi ft looked after a pot The charge lost about 1 0 per ce nt i n wei ght ; . .

th e loss i n Pb w as about 2 3 4 per cent A po t furni shed about 1 2 to ns blast .

roasted materi al p er day The cost was about $ 2 per ton charge . .

Th e proce ss has bee n replaced by blast roasti ng in a Dwi gh t Lloyd machi ne -

( 59 7) w hi c h ha s h a lve d t he co s t I t s a d d i t i o n a l di sa d v an t a ge s have been .

Pri va te co mmunicati on by O . M . Bi harz , 1 9 1 0, and W A Sm

. i th .
,
1916 .

Edi tor, E ng . Mi n . J .
,
1 9 ,
1 0 Lxxx rx ,
64 8 .
1 90 ME TALLURGY OF LE AD

the requ i reme nt of add i ng a large am ou nt of li me stone to red uce the calorifi c

p ower of t he ore and the nece ssi ty of decomp o si ng i t afterw ard , .

T he p roce ss i s very sensi ti ve to sli g ht v ari ati o ns i n compo si ti o n of ch arge

1
,

and req ui res clo se ad here nce to cert ai n proporti o ns of Si O, and PbO .

A cal cul ati on of the he at di stri buti o n i n a spe cifi c case by J W Ri ch ar ds ’

. .

sho w s th at 2 2 per ce nt of the he at p asses ofl i n g ases 1 8 per cent i s req ui red .

, .

for the de composi ti on of li mestone and 4 for th at of the si de ri te 9 per ce nt , .

°
for the ev apor ati on of moisture 2 3 per ce nt i s fou nd i n the se nsi ble he at 4 00 ,
.

C ) of the produ ct and the di flerence 2 5 per cent i s lost by r adi ati on and
.
, , .
,

co ndu cti o n .

Labor atory experi m e nts by H ofm an Reynolds Wells wi th charges wei ghi ng
8 - -

2 0 kg h ave covered the composi ti o n of ch arge pressure of bl ast ri se and f a ll

.
, ,

of temper ature and lo ss i n Pb and Ag; see also P ack ard ,

‘
.

An i nnov ati o n i n the o ri gi nal process is the ad m i ssi on of ste am wi th t he

blast 5
.T he steam i s to co nde nse i n p art i n the upper cooler laye rs of th e
ch arge to mo is te n them and th us preve nt du st i ng ; i n p art i t i s to be decomposed
,

by the glowi ng fuel form water gas and thus promote si nteri ng , ,
.

9 7 . D w i gh t L loy d P r oc ess
°—
T hi s pro ce ss difi
-
ers fro m t he i nterm i tte n t .
'

up dr aft processes so far di scussed i n th at i t work s co nti nuously wi th a do w

-
n ,

dr aft acti ng upon a thi n l ayer of ore Spre ad on and held i n pl ace by a tr aveli ng
g r a te U
.
p dr a ft p roce sse s h ave
-
the foll owi ng d i sadv a n t age s : T h ey ar e i n
term i ttent ; the pots requi re much atte nti on; the ch arges m ay co nt ai n o nly a

sm all perce nt age o f fines ; they are li able to sufier loss i n Pb as they are expo sed ,

for co nsi der able ti me to the i nflue nces of hot g ase s ; they are eve nly si ntered
and fur ni sh co nsi der a ble amou nts of fines whi ch cau se loss by dusti ng and vola

ti li z ati on and h ave to be re tre ated ; the si nter cakes h ave to be broke n whi ch
,
-

‘
Mostow i tsch, Tr A I M E 1 9 1 6, LV 74 1 . . . . .
, ,
.

Metallurgi cal Calculati ons McGrawHill Book ,

-
Co .
, NewYork , 1 9 1 8, part 1 1 1 ,

Tr A I M E , 1 90 7, xxxvrn , 1 2 6 1
. . . . . .

‘
Loc . ci t .
, p .
93 5 .

“Savelsberg , U S Patent No . . . 1 1 033 1 1 8 , July 1 4 , 1 9 1 4.

D wi ght M i n I nd 1 907 xvr 380

,
. .
, , , .

Hofm an Tr A I M E 1 910
, 755 . . . . .
, , .

D wi ght op cit 1 9 1 4 , 49 1 . .
, , .

W ork carri ed on at
Trail B C Jacobs Met Chem Eng 1 9 1 1 l x
.
, . . .
, , , 4 05 .

Sali da Colo ; Hough Mi n Sc Press 1 9 1 2 CW .

, . .
, , ,
89 5 .

Met Chem Eng

,

Corresp ondent, . . .
,
1 9 1 2 , x, 87 .

Weeks Tr A I M E , 1 91 5 .
, 71 1 .

mm 94 6
. . . .
,

Tooel e, Utah ; T ho m son -

Si cka, op . ci t .
,
1 9 1 3, ,
.

H erculaneum Mo ; Pulsi f er M i n E ng World , . 1 9 1 3 , xxx rx , 1 054 .

m
, , , .

E di tor, E ng Mi n J , 1 9 1 4 , xcv , 900 . . . .

E ast Helena, Mont ; Ri ddell , Tr A I M E , . . . . . . 1 914, 4 95 , 530 .

Newho use op ci t 1 9 1 4 , X IJ X , 53 5
m
. .
, ,

Murray , U tah ; Norton , op . ci t .

, 1 91 4, x , 4 35
E l Paso , Texas : Vai l ,
E ng . Mi n . J .
,
1 9 1 4 , xcvrrr, 4 65 .

E aster, Tr A I . . . M . E .
,
1 91 5, 7 1 6 .
1 92 ME TALLURGY OF LE AD

bi nati on form practi cally an endless conveyor wi th the conti nui ty brok en
, ,

at one p lac e i n th e ci r cui t E ach pallet i s p ro vi ded wi th fo ur wheels whi ch

.

engage w i th th e tracks or gui d es at all parts of the ci rcui t e xcept where t h e ,

pallet i s passi ng over the sucti on box and then the pallet sli des on i ts plan e d -

bottom over the planed top of the sucti on box thus m ak i ng an ai r ti gh t -

,
-

joi nt .
l
A pai r of cast steel sprocket wheels turni ng i nsi de of the co ncent ri c
- -

gui de rails l i fts the trai n of pall ets from the lower to the upper track by
-

engagi ng thei r teeth wi th the roller wheels and launches e ach pallet i n a -

hori zo ntal path under the feed hopper and i gni ti ng furnace and over t h e -

sucti o n box -
In a trai n of pall ets i n acti on all the jo i nts are kept clo sed an d
.
,

ai r ti gh t by th e pall ets bei ng push ed from be hi nd

-
At the begi nni ng and end .

of the track fo rmed by the planed top of the sucti on box there i s a plane d -

dead plate over whi ch the pallets must gli de ; wh i ch serv es to p revent any
-

F eed Be sul s txna

G at e

W ate r

T
u i ti on F urn

FI G S . 1 5 2 and 1 53 .
— D wi ght Lloyd -
st rai ght -
li ne m chi n
a e .

leak age of Afte r

a pall et passes over the sucti on box and termi nal dead
ai r .
-

plate i ts wheels engage the ends of the ci rcular di scharge gui des These are
,
-
.

adj usted wi th th e vi ew of rai si ng the pallet about 0 5 i n ve rti cal ly and th u s . .

auto m ati cally p ryi ng up the cake of si nte r and freei ng i t from t he grat e slots -
.

“ ”
A b reaki ng ro lle r prevents the p ryi ng acti o n from e xtendi ng too far back and
-

tends to fo rm a li ne of fracture Thi s roller however i s not essenti al i n all .

, ,

case s On rea chi ng th e cu rve s of th e gui des the pallets one by one drop i nto the
.
, , ,

gui des each stri kes the pallet whi ch has p receded i t and at the same ti me
, , ,

di scharge s i ts load of si nte r and shake s free the slot s of the grates The force
, .

of the b low can be regulated by the gap left i n the trai n of pallets at thi s po i nt .

The wei ght of th e trai n keeps th e pallets fed down to the lower teeth of the
sp ro cket wh eels -
.

Im p rovem ent by Law s U S Pat ent N o 1 09 759 2 M ay 1 9 1 9 1 4

,
. . .
, , .
 S MELTI NG LE AD ORE S I N TH E BLAS T F URN A CE

The mplete cycle of co as pallet operati ons i s

p ushed on fo llows: A , bei ng s

ward tangenti ally from the top of the sprocket wheels passes under the feed -

h opper where i t takes i ts lo ad i n the form of a co nti nuous even layer of

,

charge say 4 i n thi ck passes nex t unde r the i gni ter ( a furnace i n Fi g
,
.
,
.

wh ere the top surface i s ki ndled and at the same ti me comes wi thi n the i n ,

fl uence of the downward mo vi ng current of ai r i nduced by the sucti o n draft ; -

,
-

t hi s car ri es the si nteri ng acti o n progre ssi vely downward un ti l i t reache s the

g ra t e s Th e ro. a st si n teri n g a c ti on i s c omp lete th e-

c a ke i s di s c ha rge d by th e ,

p a ll et dropp i n g i n to th e d i sc h a rge g u i d e s a n d th e p a ll et c row d s i t s w a y b a ck

-

t o the spro cket wheels i s slowly rai sed to the upper tr ack s and begi ns a new
-

, ,

cy cl e .

The machi nes used formerly were smaller than tho se i n operati o n at p resent ;
th us the first machi ne erected at Sali da Colo i n Novembe r 1 908 was 1 3 by ,
.
, , ,

1 50 i n The standard machi ne found in all plants at present i s 4 2 by 2 64 i n ;

. .

i t wei ghs i ncludi ng grate bars 58 000 1b has two sucti on or wi nd boxe s 4 2 i n
,
-

, ,
.
,
-

,
.

wi d e and 1 1 ft long each wi th a sucti on pi pe 2 0 i n i n di ameter endi ng i n a suc

.
,
-

,
.
,
~

ti o n m ai n 2 4 i n i n di ameter conne cted wi th a doub le i nlet su cti o n fan

.
,
The -
.

ma chi ne i ncludi ng feed hopper i s 40 ft long and the tops of the pallets are 2 1 ft -
.
,
.

abo ve th e floo r Th e wei gh t of a pallet i ncl udi ng grate i s 800 lb

. The power .

re q ui red to dri ve th e machi ne i s from 2 to 3 h p ; th at for ope rati ng a m achi ne . .

wi t h all accessori es except the fan i s from 1 0 to 1 5 h p ; the fan proper consumes . .

fro m4 0 to 50 h p accordi ng to lo cal co ndi ti ons Th e total power consumpti on

. . .

p er m a chi ne i s t h ere fore f r om 5 0 to 65 h p M ac h i n e s are s p a c ed a t 1 8 ft . .

-
.

cen ters A machi ne wi th accessori es co sts $6000 shi ppi ng and ere cti ng i n an
.
,

ex i s ti ng bui ldi ng co sts about $6000 a bu ildi ng contai ni ng automati c fee der s , ,

et c . co st about $8000
, .

Th e mi xi ng and feedi ng of the ore charge i s see n to be accompli shed Fi g -

,
.

1 56 by deli veri ng the components i nto a recei vi ng hopper p rovi ded wi th a gate
,

to regulate the di scharge and wi th an endle ss belt ( automati c feeder) deli veri ng ,

i n to a ho ri zo ntal mi x er where the i ngredi ents are mi x ed and the water sprayed , ,

fro m a stand pi pe i s i ncorporated The mi xer di scharges through a chute i nto

-

,
.

t h e feed hopper of the si nteri ng machi ne

-
.

Th e mi xer whi le very efl ecti ve consum ,

es co nsi derable power and the blades , ,

o f t he revolvi ng shaft wear out qui ckly Both di sadvantages have been over .

com e by the pla te feeder shown i n Fi g 1 57 The ore arri ves partly mi x ed on -
. .

th e belt and i s di scharged by Rob i ns tri pper 6 i nto recei vi ng hopper d wh e re i t , , , ,

recei ves th e necessary amount of water through spray pi pe e Beneath hopper -

, .
,

11 rota tes ci rcular fee d ta b le f p rovi ded w

,
i th sta ti onary pi vote d rabb le s ( not
-

, ,

sh ow n si mi lar to tho se of the Brunton or Godfrey fur nace Fi gs 1 3 1 1 3 2 and — .

, ,

1 33 1 3 7) for mi xi ng the ore and movi ng i t from center to peri phe ry and a
-

pi voted scraper (not shown) to di scharge the mi xed and moi stened ore i nto
feed hOp p er g whence i t drops on to i ncli ned plate h and fo rms ore bed i on
-

, , , ,
-

, ,

p al l e t s j tr a ve li,n g i n the ,
d i r ec t i o n of t h e arrow H a n d ch a i n k se rv e s to .
-

, ,

change th e di re cti on of the pi voted rabb les and to adjust the feedi ng In form .

i ng ore bed i the coarser parti cl es roll down the i ncli ned surface on to the
-

, ,

13
1 94 ME TALLURG Y OF LE AD

pallets and form a porous bed whi ch i s esse nti al for good work As the pallet s
,
.

travel u nder the i gni ter the finer parti cles at the top of t he tri ang ular ore hea p
,
-

are pushed back over the coarser by th e ver ti cal si de of the feed hopper Thi s -
.

M an of M ixi ng Bi ns Bi ns and Feeder:

Frcs. 1 54 to 1 56 .
— Plant of D wi ght Lloyd
-
st rai ght -
a machi ne .

t ermi nates 4 i n above

. the pallets and thus furni shes the de si red uni form laye r
of ore whi ch i n the standard m achi ne i s 4 2 i n w
,
i de and 4 i n t hi ck . . .

B efore t hi s manner of di str i buti ng ore mi xture on the grate w as devi sed
-

,
1 96 ME TALLURG Y OF LEAD

machi nes frequently had two feed hoppers one back of the other th e hopper -

, ,

farther away from the sucti on box recei vi ng coarse ore mi xture or crushed - -

li mestone th e o th er fine materi al

,
The two hoppers are sti ll i n place w i th older .

machi nes but onl y one i s at p resent i n operati on

,
.

When the si nter cake has passed the sucti on box and a pi ece i s broken ofl to - -

be di scharged the break i s often rather j agged In order to obtai n a strai ght
,
.

li ne b reak a so called M arker has been i ntrodu ced at one plant between the
,
-

feed and i gni ter whi ch makes at the end of a pallet an indenta ti on on the ore sur -

face and causes th e break to form alo ng a strai ght li ne Thi s si mple and efl ect .

i ve devi ce i s shown i n Fi gs 1 58 and 1 59 H o ri zo a shaft a revolvi ng i n boxes . .

, , ,

6 attached to 8 i h I beams car ri e s two rol lers c dri ven by traveli ng pallets ;
,
-
.
-

, , ,

roll ers c are joi ne d by fl exi ble i ron bar e 1 5 by

, , 5 i h w h i ch ma k es a cut , , . .
,

i nto the ore bed wi th eve ry revo lut i on of the shaft

-
.

Ton of Be
S OUT H EN D ELEVATIO N
O N LINE B B -

FI G S . 1 58 and 1 59 .
— Marker for D wi ght -
Lloyd si nt eri ng m hi n ac e .

The h ge was ori gi nally and i n some i nsta nces still i s i gni ted from a
ore c ar -

, ,

small suspende d coal burni ng fu rna ce bui lt of ti les Fi gs 1 52 and 1 53 T he grate

-

,
. .

has the same wi dth as the pallet ; i t i s about 1 5 i n wi de and burns abo ut .
,

l b co al i n 2 4 hr The flame after passi ng over th e firebri dge i s deflected

. .
, ,

do w nw ard upo n th e ore by a bri ck cu rtai n whi ch can be rai se d and lowe red ,

and i s t h e n drawn up w ard by th e natural draft of a small stack .

Gaso li ne and si mi lar li gh t hy drocarbons have b ee n u se d to ki ndle th e sur

face of the ore but have bee n abandoned on account of the hi gh p ri ces They
,
.

°
have been replace d by re siduum oi l of about 2 6 Bé At p resent mo st m achi nes .

use an oi l bu rne r; of the many suggested the J F Austi n bur ner or i gni ter
-
‘
.
, .

i s fo und almost everywhe re —

I t i s shown i n Fi gs 1 60 1 63 In Fi gs 1 60 . . . .

and 1 6 1 A repre sents a steel fram

,
e of the D wi ght Lloyd machi ne B th e feed -

h0p p er C t h e pallet D the sp rocket wheel F the ore charge G the i gni te r and H
, , ,
-

, ,

the sucti on box Igni ter G consi sts of an arched ref ractory firi ng chamber sus
-
.

pended by adjustable rods i n front of feed hopper B The chamber O pen along -

, .
,

t he larger part of the botto m i s fo rmed of two ki nds of arch e d b ri ck e nclo sed ,

by an i ron casi ng ; the si de bri cks Fi g 1 63 have no bottom but the two end -

, .
, ,

1
U S Patent N o
. . . 1 1 79390 , Ap ril 1 8, 191 6; Mi n . E ng . World , 191 6, x 1 v, . 1 36 .
 S M ELTI NG LE AD ORE S I N TH E BLA S T F URN ACE 197

FIG . 1 61 .

Fro . 1 62 . FIG . 1 63 .

— F Austi n oil igni t er

Free. 1 60 to 1 63.
J . . .

m
Oi l RECERVOlR TANK
l Y R R. TANK CA”

“l m m
.

. uss r

ALst svx rn
LONGITUDINAL s ecrlbi r
' ‘

ou
F105 . 1 64 and 1 6 5 — Pl an
. and longi tudi nal elevati on of oil and ai r-
feeds to Aust i n igni ters.
 .

198 ME TALLURGY or LE AD

bri cks Fi g 1 62 have bottoms and openi ngs through whi ch pass the oi l and
, .
,

ai r pi pe s I and J
-
,
The oi l flame e nters the combusti on chamber and fills i t
.

wi th flame As the chamber extends on ei ther si de beyond the pallets the

.
,

whole surface of the charge i s uni fo rmly hea ted as i t passes beneath the chamber .

The do w ndraft of sucti on box H draws downward the flam -

, e and hot ,

Fl cs . 1 66 to 1 8
6 —.Stewart grate for D wight Lloyd machine
-
.

The general arrangement of oi l for two D wi ght Lloyd

and ai r supply
- -

machi nes wi th Austi n i ngni ters i s shown i n plan and longi tudi nal se cti on
i n Fi gs 1 64 and 1 65 whi ch are clea r wi thout fur ther comment
.
,
The ai r .

pressure i s gi ven as bei ng 5 lb p er sq i n ; i n some plants the oi l p ressure

. . .
-

—
rea ches 2 0 2 5 lb and the ai r pressure as much as 40 lb per sq i n
-
. .
, .
.

The pall ets Fi g s 1 52 and 1 53 usually are cast i ron frames and have herri ng
, .
,
-

one grate s In some i nstances the frame i s a malleab le casti ng and the grate
.
,
ME TALLURGY
'
OF LE AD

— d 6 0
.

O
a
e d
0
5 w v
—
5
fi
c
o
3a
a B
.
a n 8
u
0
£
n
c y
1
m
0 a
n
m
o
Q e
u3 w
e 8
.
. 6 a
e 0
9
0 85 E
m
z3 e vo EJn3 .
5 39 8
0
o
3 di a
b
g3 Ec
n ,

a—
-

& fi
e
e e
£ a 3 a
m8 n fi2 n

m u < 0 2> 0 3hc

"

3
e
r
j
m
o
9 .

h 0 3
 S MELTI N G LE AD ORE S I N TH E BLAS T F URN ACE

Th e peed of travel of the pallets whi ch ranged from 7 to 1 0 i n and reached

s .

perhaps 1 5 i n p er m i n has been advanced to as much as 30 i n wi th a co rre

. .
,
.

spondi ng i ncrease i n to nnage from 50 to 2 00 to ns and over Thi s has b een .

accompani ed by a ri se i n the S co ntent of the si nter whi ch however di d not

-

, ,

corres po nd as m i gh t be expected to the quanti ty of ore trea ted

, ,
At the Tooele .

plant the speed of travel of pallets was 1 3 i n per mi n and the dai ly product
1
. .
,

0 —
7 95 to ns ; a s li ght a dv an ce i n speed ga ve an i nfe ri or produ ct wi th hi gh S
co nte nt ; an i ncrease to 2 6 and 30 i n m ore than doubled the pro duct whi ch .

had a good structure and a lowS content From thi s i t appears that i n i n
-
.

creasi ng the speed of travel one reach es a hal ti ng p o i nt ; but tha t as soon as one -

gets we ll beyond i t newcondi ti ons ari se whi ch perm i t a qui cker travel
, .

An e xp lanat i on m ay be found i n the fact tha t the charges bei ng fed qui ckly

do no t pack pass qui ckly under the i gni te r and do not m atte and can stand
, ,

more water than wi th a slow travel ; the greater the permi ssi ble water the more ,

porous the charge and the more qui ck the roast Duri ng 5 month s th e
,
.

avera ge analysi s of the ore m i xture w as Pb Cu Si 02

Fe M n
-
S CaO Zn per cent Ag and Au oz .
, .

per ton ; that of the product : Pb Cu Si 02 Fe Mn -

S CaO Zn p er ce nt Ag an d A u oz per to
. n , A scree n . .

analysi s of the ore t reated i n 4 week s gi ve s the d ata shown i n Tab le 4 8 .

TABLE 48.
— SCRE E N AN ALYS IS or On : Mxx ruas ,
Toos u z, UT AH
-

December , 191 5
Si ze, mesh

— 1 00

The mount of gri zzly fines vari e d from 1 5 to 2 0 per cent A scree n and a
a .

chemi cal analy si s are gi ve n i n Tab le 4 9 The screeni ngs are see n to assay .

5
—6
p er c e nt S w he re.as the c
,ake d p ro du ct co nt ai ns 2 —
3 p er ce nt 8 Ret urni ng . .

the gri zz ly scree ni ngs to the ore charge makes th e latte r po rou s and f aci li tates
-

the roast T h e re i s thus obtai ned wi th a large to nnage for ore a doub le
.
,

treatment of th e hi gh S pro duct -

.

Pri vat e co mmuni ca ti on by W . W rai th ,

February, 1 9 1 6, and i
p vat e ne
r ws , J uly , 1 9 1 6 .
202 ME TALLURG Y OF LE AD

TABLE 49
—.Scu m AN D CE E N I CAL AN ALYSE S or GarzzLx FI NE S , T00E LE , UrAn

The verage loss i n Pb wi th hi gh speed travel of pallets

a -
is from 1 .
5 t o 2

per ce nt A few
. d a ta cove ri ng lo sses are gi ve n i n Tab le 50 .

TAB LE 50 — Lo ss or
. Ms rAL IN HIGH -
S PE E D D W IGHT LLOYD MACH I NE ( T 00E LE )
-

Loss, per cent .

denot es an a ppa ent gai n

r .

The vacuum i n the sucti on box whi ch i s governed largely by t he -

densi ty of the charge shows a range of from 5 to 1 0 oz

,
.

Igni ti on fuel has been taken up on page 1 96 Th e amount of oi l req ui red .

per ton of charge ranges usually from to g a l .

The charge i s made up of rawand p re roasted sulphi des matte sili ci ous -

, ,

ores and some ti mes li me stone The use of pre roasted pyri te concentrate
, .
-

as i ron flux often shows a tende ncy to hi nder the agglome rati o n of p art i cl es .

An addi ti o n of m atte usually corrects t hi s evi l The si ze of charge compo nents .

Sho w s a range from i n to 2 00 mesh -

I t i s esse nti al that the i ngredi ents
.
-
.

of a charge be well mi xed and uni formly moi stened The S content vari es .
-

between 1 1 and 1 4 p er cent The amount of Pb covers a large range ex te ndi ng

.

from 1 5 to 4 7 and even 50 per cent The percentage of Si 02 i s 1 0 to 2 5 that of

,
.
,

FeO i s about 1 5X Si Og; C8 0 i s usually lower th an FeO

. .

In maki ng up a charge the si ze of parti cle s deserves about as much con

,

si derati o n as the chemi cal co m po si ti on as i t i s of vi tal i mportance that the ,

charge be porous The quanti ty of water added vari es wi th the calo rific
.

p ower of t he cha rge an d the pe rc e n ta g e of fi ne s ; the u su al range i s from 5

to 1 0 per cent ; the m et the charge compo nent s the greate r h as to be the
(
-
.

water co ntent The depth of charge i s u ni fo rmly 4 i n Wi th the von Schli p

-
. .

p e nbac h ta b le m ac h i n
-
e th e dept h i s 1 0 i n for th e purpo se of obtai ni ng .
,
204 ME TALLU RG Y OF LE A D

21 ft 6 i n i n di ameter and 2 2 ft 1 1 56 i n hi gh and four stand

. . . .
, Dw ight
Lloyd machi nes treati ng each about 2 00 to ns i n 2 4 hr D etai ls of the Wedge
.

furnace have bee n gi ven i n connecti on wi th Fi gs 1 39 and 1 40 ; those of the

.

Dwi gh t Lloyd machi ne have just been tak en up The general arrangem
-
. ent of

gi ven wi th much detai l i n the drawi ngs and needs no fur ther comment
is .

i n vi ew of what has already been sai d

1 00 Double Treatm
.

. ent — By thi s term are understoo d the operati ons of

rough roasting a large am
-
ount of ore i n a Dwi ght Lloyd machi ne and fini shi ng
-

,
 SMELTI NG LEAD ORE S I N TH E BLA S T F URN A CE

the rough -
roasted mate rial ei ther i n
a H u nti ngto n H eberl ei n pot or i n a second -

Dw i gh t Lloyd machi ne i n order to obtai n a porous si nte red produ ct low i n

-

S cont ent
-
.

A combi nati on of D L and .

-
.

H 81 H
. treatment has been .

worked out sati sfactorily i n two

plants ’
The D L mi x tu re con
.
-
.

tains e g S i o, 9 Fe( M n)O 1 6

, . .
, , ,

Ca( Mg) O —
S 1 0 1 1 5 Zn .
,

—
Pb 2 8 32 per ce nt Cu .
,

trace The pallets are moved at

.

the hi gh speed of 3 7 4 8 i n p er
— .

mi n so that about 2 50 tons

.
,

charge are p ut through i n 2 4 hr ; .

the S content of the charge

-

whi ch may go as hi gh as 1 5 per

cent —
i s reduced to 6 7 per cent .
,
.

The p roduct i s broken i n a

Willi am s hi nged hammer crush er
to pass a i n scree n the n -
.
,

m i xed w —
i th 1 0 1 2 per cent li me .

stone cru sh e d to th e same si ze ,

i nd blo w n i n an H 81 H pot . . .

A charge of 1 2 tons mi xture

—
furni shes i n 5 6 hr 9 9 5 tons — . .

sintered product w —
i th 1 5 2 5 per . .

cent 8 of whi ch 4 0 per ce nt i s

.
,
.

sulp hate S The pot i s gi ven first-

.

a 2 ln gra te dressi ng of si li ci ou s
-
.
-

ore th en a r i n layer of glowi ng

,
-
.

coal from a Go dfrey furnace ,

and finall y i ts ll charge to be

fu
blow —
.

n at a p ressure of 1 2 1 4 oz .

The advan tages of the do uble

treatm ent are that the double
roast f urnis hes mo re ZnO than

does a nor m al si ngle roast that ,

the m atte fall i s grea tly redu ced -

and wi th i t the dange r of zi nc

mush and that the di rect output

,

of lead i s largely i ncreased .

The se advantages mo re th an
balance the co st of the addi ti onal ope rati on .

Ri ddell, Tr A I M E . . . .
, 1 9 1 4 , xu x , 53 1 .

m
Hof an, p ri vat e not es, July , 1 91 6 .
206 ME TALLURG Y OF LE AD

mbi nati on of two D L machi nes the mode of operati ng i s si mi lar

In the co .
-
.

to the double trea tm ent j us t descri bed It was started by H L H yde in . . .

Australi a about 1 9 1 1 The o ri gi nal ch arge crush ed to JvQ i n si ze conta i ni ng .

,
-
.
, ,

. .
— ,
— — —
e g Slo g 8 1 0 FcO 2 8 30 CaO 4 5 S 1 2 1 3 p er cent i s run on the m
, achi ne , ,
.
,

wi th pallets traveli ng at a speed of 30 i n per mi n The rough roasted p artly . .

-

caked m ateri al retai ns 7 8 per ce nt S i s crush ed i n a Jefi rey swi ng h am

— mer .
,
-

machi ne to pass a ln screen and i s retreated wi thout the addi ti on O f li m e -

.
,

stone the p allets traveli ng at a rate of 2 2 i n p er m

, i n The fini sh ed p roduct . .
,

whi ch i s i mperfectly si ntered but practi cally free from fines retai ns about ,

2 p er ce nt S . .

The p racti ce i naugurated by Wrai th at Tooele (page 20 1 ) of havi ng a

q ui ck travel Of pallets and of separati ng hi gh S fines from lowS si nt er by ,
- -

means of a gri zzly i s actually a double treatment except that onl y hi gh S , ,

-

fines whi ch form 1 5 2 0 per cent of the ori gi nal charge go to be treated agai n
,
-

.
, .

The advantage of thi s m ethod of worki ng i s evi dent especi ally w i th ores t hat ,

contai n li ttle blende .

The general omp of i ntermi ttent up d raft and conti nuous

c down draft ari son - -

blast roasti ng , gi ven i n 59 7, i s here supplemented by the work of N ort on

1

at M urray Utah and of Ri ddell at East H elena M ont The former on the
’
.
, , , ,

whole favors the H , H the latter the D L process A sum mary of the . .
,
.
-
. .

co ncl u si o ns arri ved at by the two superi ntendents of these promi nent pla nts is

gi ve n i n T ab le 5 1 .

T AB LE 5 1 — CO N PA
.EI SO N or H a N cro N -
H E B E E LE I N AN n D WI GH T LLOYD -
PR OCESS E S

Advantage i n favor of

At East Helena

1 . Cost of i nstallati on
H . H
3 Ada
.
p tabili ty to ch arge

4 Metal loss
.

5 Physi cal
. condi ti on of p roduct

Theows agreement as regards i tem s 1 3 and 4 The di sp uted

table sh , . .

headi ngs 2 and 5 find i n a general w ay thei r e xp lanat i on i n the fact th at , ,

wherever a new i nstallati on i s made the D L i s preferred to the H 81 H , .

-
. . .
,

and that the sli ghtly greater co st of the H 81 H i n a large plant i s not of . .

sufi ci ent i mportance to exp lai n the p reference shown to the D L .

-
.

In compari ng the behavi or of the H 81 H and the D L products i n th e . . .

-
.

blast furnace Norton found that i n smelti ng

-
’
to ns charge wi th 9 50 tons
,

or 1 1 5 per cent coke he Obtai ned wi th the H 81 H materi al slags assayi ng

. .
,
. .

p er ce nt Pb w hile wi th D L m ateri al they ass ayed .

p er cent He
,
.
-
. .

Tr A I . . . M . E .
, 1 9 1 4 , xu x, 485
.

Op . ci t .
, 49 5 .

0p ci t , 4 90 . . .
208 ME TALLU RGY OF LE AD

ette oblong bri ck furnaces common i n E uropean plants were i ntroduced at , ,

E ureka N ev ; ten years later the Oblong furnace had superseded the polygonal
,
.

and ci rcular forms C ast i ro n water j ackets began to replace in 1 872 t he bri ck - -
.

work of th e smelti ng zone 1

In 1 8 71 Arents had i nvente d hi s si pho n tap
’
.

I n verti cal se cti o n the fur naces at fi rst we re p ri sm ati c late r the si des were made ,

to taper to ward the bottom and lastly the tape ri ng Si des recei ved bo sh es The , .

cru ci bl e ori gi nally partly i nte rnal and partly ex te rnal was replaced by the ,

i nternal fo rm wi th the adop ti o n of the Lfi rm an tappi ng j ack et E x te rnal -

.

cruci b le s have been patented

’
but are not i n use as far as the wri ter i s , ,

aware .Th us about 1 880 the leadi ng features common to all ore fu rnaces ,
-

were establi shed Th e furnaces are oblong i n horiz o ntal secti on have t aperi ng
.
,

si des w i th boshes st rai ght ends a water j acketed smel ti ng zone an i n ternal
, ,
- -

cruci b le and an Arents si pho n tap

,
The ci rcul ar water j ack eted furnace is .
-

used only to smelt at i nte rvals small quanti ti es of i ntermedi ary produ cts Of a
refinery The b ri ck shaft common wi th most ore furnaces is nowgi vi ng way
.

to steel wate r j ackets -

.

Wi th the i ncrease of siz e of furnaces and of smelti ng plants the movi ng of

ore flux and fuel by teams and wheelbarro ws became i mpossi ble and had to be
, ,

replaced by me chani cal tracti on and mani p ulati on .

The accesso ry apparatus to remove the slag from the first sm all si ze furnaces -

treati ng mai nly o xi de ore consi sted of si mple fo rms of slag po ts Wi th the -
.

adve nt of sul phi de ore provi si o n had to be made to colle ct m atte M a tte .

settli ng po ts use d at first have gi ve n w ay to oblo ng fore hear ths Fi nally -

.
,

the di sposal of the i ncreasi ng amounts of i nte rmedi ary and final p rod uct s
nece ssi tated t he i ntroducti o n of steam comp resse d ai r and electri c power SO ,
-

, ,

that at present mechani cal tracti on and mani pulati on has become typi cal .

Fo rmerly no provi si on w as m
,
ade to save the value s contai ned i n the

waste gases ; later dust chambers we re provi ded and the se have been supple
, ,

mented by filter bag houses and electri c preci pi tati ng apparatus -

.

The p ri m i ti ve blowi ng m achi nes used at fi rst h ave bee n scrapped ; rotary

pressure blo wers of the Roots type have been i nstall ed and the i r sup rem acy ,

i s now bei ng challenged by tu rbo blowers .

Blast furnace Ge ne ral - 1 — Fi ve b las t furnaces i n operati on at some of t he .

-

leadi ng sme lte ri e s are repre sented i n Fi gs 1 72 1 85 Fi gs 1 72 and 1 73 Sho w .

-

. .

the standard fu rnace bui lt by the Colo rado I ro n Work s D e nve r Colo abou t , , .
,

1 890 ; Fi gs 1 74 and 1 75 rep re sent the stand ard furnace of the Internati o nal
.

1
D aggett Hofman M i n I M -

,
. .
, 90 5, x rv, 4 09
1 .

Hahn Ei lers Raymond Tr- -

, . A I M E , 1 8 7 1 73 ,
. .
— . . 1 , 1 08 .

Arents, E ng . Mi n . J .
, 1 88 5, X L, 2 8 7 .

D evereux , D ecember 6 N o 3 74 2 39 ; 1 888 Ap ri l 1 7 N os 38 1 1 1 8 and 381 1 1 9 ;

1 8 87, , .
, , .

J une 1 2, No .
384 34 9 ; 1 889 J uly 2 3 N os 4 0 733 5 4 0 7336 and 4 0 733 7 ; D ecem
,ber 1 7 N o s ,
.
, , , .

41 73 1 4 and 4 1 73 1 5 ; 1 890, May 6 No ,

.
4 2 70 58 .

Konc ,
888, O ct mann
ober 9, N o 390 78 5 1 . .

Wilson, 1 889 May 2 1 , N o 4 038 1 5, and others ,

. .

m
Pal er, Tr A I M E , 1 9 1 4 , xu x , 50 7
. . . . . .

D wi ght , E ng . Mi n . J .
, 1 9 1 6, CH , 671 .
S M ELTI N G LE AD ORES I N TH E BLAS T F URN ACE 209
2 10 ME TALLURGY OF LE AD

Smel ti ng CO Tooele , Utah ,

de si gned by W Wrai th ; Fi gs 1 76 1 79 one of the . .
-

furnaces of the Co nsoli dated Mi ni ng and Smelti ng Co of Canada Trail B C .

, , . .
,

desi gned by R H Stewart ; Fi gs 1 80 and 1 8 1 g i ve the details and Fi gs 1 8 2 and

. . . .

1 83 two elev ati ons of the f ur nace de si gned by S Jame s and i nstalled by the .

Traylor E ngi neeri ng Co Allentown Pa at the works of the N orthpo rt .

, ,
.
,

Smelti ng and Refini ng Co N orthpo rt Wash ; Fi gs 1 84 and 1 8 5 i s the fu rnace .

, ,
. .

of the B unker H i ll and Sulli van Mi ni ng and Concentrati ng Co at Kellogg .

,

I daho bui lt by the same fi rmaccordi ng to the plans of Bradley Brufi and
, , ,

Labar the San Franci sco ,

These drawi ngs are sufi ci ent to serve as a b asi s .

for the di scussi on of the pri nci pal feature s of modern blast furnaces O ther -
.

i ll ust rati ons wi ll be gi ven to b ri ng out details not shown w i th sufi ci ent
—
cl earness i n Fi gs 1 72 1 8 5 . .

FI GS . 1 74 and 1 75 — Blast urnace, I nternati onal S . f melti ng Co .

,
Tooele, Utah .

In Table 53 embled the pri nci pal facts of some of the leadi ng
are ass

blast furnaces i n Operati on at pre se nt O ther tables repre senti ng the ea rli e r .
,

p racti ce have been pub li shed by Croll Kochi nke Iles M

,
1 ’
Borche rs ‘
, , ,
.
,

Ralli and Co lli ns H F

‘
.
, ,

1 03 Foundati on
.
— The wei ght of a lead blast f urnace wi th b ri ck Shaft i s
.

about 1 00 to ns The shaft the h eavi est part i s carri ed by four cas t i ron or
.
, ,
-

steel col um ns Th ough the structure as a whole i s not very heavy consi derab le
.
,

attenti o n has to be gi ven to the foundati o n Its depth wi ll depe nd upon th e .

char acter of t he subj ace nt grou nd If bed rock i s e xpo sed thi s will furni sh .
-

as good a found ati on as can be wi she d N ext i n o rder comes hard pan a m ix .
,

Eng . Mi n . J .
, 1 89 8, m , 639 .

Frei berg J ahrb , 2 1 6 ; M i n I nd x , 4 30 ; correcti on

’
. . 1 90 1 , . .
, 1 90 1 , by Cap .
, Oest Z t B erg
. . .

H i nton )" 1 90 2 , L, 1 4 7 ; M i n I nd 1 90 2 XI 44 2
. .
, , ,
.

“Lead Smelti ng,

”
W iley NewYork 1 90 2, , , 4 8, 4 9 .

M etall urgi e 1 90 7 Iv, , , 1 00 .

1 Rev Un Mi n , 1 9 1 1 ,
. . . xxx rv, 2 1 6 .

1 “Lead ” Li i ncott Philadel hi a 1 9 1 0,

, pp p , . 31 2 .
21 2 ME TALLURGY OF LE A D

ture of gravel clay and sand whi ch has a bea ring power of 4 t ons per sq ft If
, , , . .

there i s loose soil or gravel coveri ng bed rock or hard p an not over 1 0 ft deep
-

.
,

i t i s best to excavate until thi s i s reached ; otherwi se a dep th of 5 ft will usually .

be sufi ci ent to start the m aso nry below fro st li ne and to gi ve the foundati on -

the requi si te strength Wi th very loose soil whi ch has a beari ng power of 2
.
,

tons per sq ft i t used to be customary to place on the bottom of the p i t two lay
. .
,

ers of 3 or 4 i n p lank s sp i ked cro ssw

-
. i se together and upon th at to b uild the ,

foundati on At present the start i s made wi th a 1 2 i n layer of cement con

.
-
.

FI C . 1 79.
— Blast furnace , Consolidated Mi ni ng and S melti ng CO . of Canada, Trail , B C . .

c rete whi ch has a beari ng power of 4 tons per sq ft Wh atever me thod i s used . .
,

i t i s e sse nti al that the foundati o n ex tend from 2 to 3 ft beyond the bed plate and .
-

the fo ur supporti ng co lum ns .

The foundati o n use d to be bui lt of undressed rock well rammed i nto place the ,

largest pi eces be i ng used for corne rs and care be i ng take n to fill up the erev
,

i ce s and jo i nts wi th as m any spalls as po ssi b le ; the who le was well grouted w i th a
mi xt ure of four parts of li me mo rtar and one part of cement The top must of .

cou rse be sm oo th and hori zo ntal and was usually made of b ri ck Thi s method
,
.

has bee n replace d i n large p art by ceme nt co ncrete whi ch i s preferable and ,

usu y a ll ch ea per If one fur nac

.e i s i n oper ati o n and a seco nd one i s t o be ,
 S ME LTI N G LE AD ORE S I N THE BLAs T F URN A CE

erected the excavate d p i t i s filled wi th broke n slag and li qui d slag i s poured i nto
, ,

close t he ca vi ti es and to cement the lumps The top i s evened and leveled by .

maki ng sh allow rectangular areas surrounded by sand or pi eces of structural

i ron and filli ng them wi th li qui d slag
, Any ri dges or o ther rough p arts are re .

moved by chi ppi ng Fi lli ng the excavated space wi th li qui d Slag i s a si mple
.

O pe rati on but not qui te as sati sfactory as th e one outli ned becau se Slag when
, ,

coo led qui ckly becomes glassy i s b ri ttle and cracks readily , , .

O n the fo undati on i s spread a thi n lay er of clay mortar upon whi ch i s placed -

the bed plate (y Fi gs 1 73 1 75 1 80

'
-

,
a steel plate about
.
,
i n thi ck whi ch
, , .
,

prevents any lead whi ch has traveled downward through the joi nts i n the
b ri ckwork of the cruci ble from penetrati ng i nto the foundati on Followi ng
,
.

the example of some copper m atti ng furnaces a few lead furnaces h ave been -

buil t wi th an ai r space benea th a cast i ron bottom plate As there i s never an

- -
.

exce ss of hea t i n the cru ci ble of a lead furnace thi s constru cti on whi ch i ncre ase s , ,

t h e lo ss of heat has not found favor , .

’
1 04 Shaft
.
— The le adi ng poi nts to be consi dered are the hei ght the ho ri ,

zonta l and verti cal secti ons the bui ldi ng materi al and the di sposi ti on of the
, ,

feedi ng and gas wi thdrawi ng openi ngs

-
.

1 05 H eight
.
— Th i s term i s i ntended to desi gnate the verti cal di stance of the
sh aft whi ch i s the rm ally and chemi cally acti ve i e the worki ng hei gh t or smelt ,
. .
,

i ng column I t exte nds from the center of tuy e res to feed floor i n fur
.
-

naces from whi ch the gases are w i thdrawn at the top ( Fi gs 1 77 1 80 1 83) and to .
, ,

t he lower edge of the down take i f the gases are wi thdrawn be neath the feed
-

,
.

Som eti mes there i s a difierence of 1 0 ft between the two but usually i t does not ex .
,

ceed 5 ft ( Fi g s 1 73
. .

About 2 0 years ago the di stance from tuy eres to feed floor used to be from -

1 0 to 1 2 ft ; i t w as t he n i ncrease d to 1 4 and later to 1 6 ft

. whi ch i s a common .
,

di m ensi on now although i t reaches 2 0 and even 2 4 ft ( Sulphi de Corporati on

,
.
,

T a b le The i ncrease i n hei ght has been necessi tated by the greater vol
um e and pre ssure of blast requi red by the enlargement of th e di stance between
,

t uy e res to i ncrease the cap aci ty and the sm elti ng power of a furnace and by the ,

si li ci o us and cal careous slags whi ch have replaced those runni ng lowi n Si Og and

hi gh i n F00 Wh ereas the blast pressure used to be from 8 to 1 0 oz per sq i n

.
-
. . .
,

i t r anges at prese nt from 30 to 40 oz and i n the case of the Sulphi de Corporati on .

,

reach es 70 oz (Table .

1 06 H ori zontal S ecti on

.
— In § 1 0 2 i t was stated th at w i th ore furnace s the
.

ob l ong rectangular secti o n had super seded th e ci r cular The ci rcular furnace .

gi ves excellent re sul t s as regards quali ty of work ; there i s an even di stri buti on
of blast and heat and the lo ss of heat by radi ati on i s the least possi ble as the
, ,

fu rnace offers the largest cro ss se cti onal area for the sm alle st ci rcumference -
.

Th e drawback li es i n the quanti ty of the wo rk whi ch i s li mi te d Si nce the di , ,

am eter at t he t uyére se cti o n ought not to exceed 60 i n

-
Wi th the charge made .

up la rgely of fine materi al the usual di stance was 4 2 i n ; wi th blast roasted ore
,
.

thi s di mensi on has bee n rai sed wi thout trouble to 54 i n al though 44 and 4 8 i n . .

are t he more commo n figures .

2 14 M E TALLURG Y OF LE A D

Fro . 1 80 .
— Blast furnace Northport Smelti ng and
, Refini ng Co .
,
Northport Wash ;
, . det ai ls .
21 6 ME TALLURGY OF LE AD

00! B and

' "

0 o Dr
. .

5 W at er

28 Beet l e
a B last G m

F108 . 1 8 2 and 1 83 . , p m
— Blast furnace North ort S elti n
g and Refini ng Co .
,
Northport ,

el evati ons
.
S M ELTI N G LEAD ORE S I N TH E BLA S T F URNA CE
21 8 ME TALLURCY OF LEAD

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220 ME TALLURCY OF LEAD

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S M ELTI N G LEA D ORE S I N TH E BLAS T F URN ACE 22 1

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222 ME TALLURGY OF LEA D

In the early ei gh ti es M thewso n p laced water cooled tuyere nozz les

E P . . a - -
.

Fi gs 1 86 and 1 8 7 i n the tuyere openi ngs of the water j ack ets so as to project 6
.
,
- -

i n i nto the 60 by 1 2 0 i n f urnaces of Pueblo Colo and thus red uced th e di s

.
-
.
, .
,

tance betw een tuye res to 4 8 i n H i s smelti ng power wi th si x 4 i n t uyeres on

.
-
.

a si d e and a bl ast pressure of 2 lb p er sq i n w

-
as zoo tons of m edi umopen charge
. . .
-
,

contai ni ng Pb 1 0 and m atte fall p er cent w i t h 1 0 p er c-

ent cok e ; th e sl ags .
, .

made bei ng Si 03 36 FeO 32 33 C9 0 1 8 p er cent ; and Si 03 36 FeO 2 8 2 9

—
, , .
,
-

C8 0 2 0 p er cent .

The reason for li m i ti ng the di stance between tuveres i s the great blast pres -

sure req ui r ed to penetrate t he ch arge whi ch wo uld cause excessi ve vola ti li za ,

ti on of lead and red uc ti on of Pegos For large q uanti ti es of ore the oblong form .

Fros . 1 86 and 1 8 7 — Mathewso n . w at er cooled -

tuyere nozzle -
.

i s therefore the proper one as the tuyere sec ti on can be enlarged by m

, aki ng -

the furnace longer wi tho ut i ncreasi ng the di stance between t uyeres Th us the .

length of oblong furnaces was at first do ubled fromthe old 60 to n o i n ; later i t .

was further i ncreased to 1 60 and 1 80 i n ( see Table It i s an open que s ti on .

whether furnaces of such lengths are not too long A norm al crewcan serve a .

furnace 1 52 i n long ; i f thi s di mensi on i s i ncreased ext ra men are necessary

.
, ,

and the addi t i onal tonnage ob tai ned i s not eq ui val ent to the i ncrease i n cost of

labor Many furnace men hold that 1 52 i n i s the greatest econo m

.
-
i c lengt h of .

furnace wi th a si ngle slag tap ; others draw the li ne at 1 9 2 i n It i s of co urse

-

.
, ,

possi ble to follow the example set by copper mat ti ng furnaces and have larger
l -

f urnaces wi th a double com plement of slag taps and lead wells but the smel ti ng - -

of lead ores i s a more deli cate matter than that of copper ores In case of .

unsati sfactory work i t i s usually cheaper to blow down a furnace and star t
,

fresh i nstead of attempti ng to nurse i t back to normal work Wi th a copper .

furnace thi s i s done more q ui ckly than wi th a lead furnace and i nvolvas less ,

loss of metal .

The larger and correspo ndi ngly hi gher f urnaces have shown a greater sm el t

i ng power than w as exp ec ted fromthe i ncreased hear th area and the i ncreased ,

tonnage has b een acco m pani ed by a lower fuel consumpti on .

See H ofman Metallurgy of COpp er McGrawH ill Book Co NewYork 1 9 1 8 x78

,
”
,
-
.
, , , .
 ME TALL URGY OF L E AD

Fro
. 1 88
.
— Blast f urnace
,
mania Lead W
Ger orks, Sal t Lake Ci ty
.
 S M E LTI N G LE AD ORE S I N TH E BLAS T F URN ACE

they were bolted together and screwed to the capi tal s of the pi llars The cast .

iron pl ates were not fastened to the b eams but rested freely up o n them By , .

thi s arrange ment

ppor ti ng plates and shaft co uld expand i ndependently
, su

of one ano ther w i thout endangeri ng the stabi li ty of the shaf t The nex t i m .

p rov em en t w a s th e i nt ro d uc ti on of br i ck arch e s w hi ch suppor t ed the w a ll s of th e

shaf t and threw the wei gh t upon th e pillars ; the lat eral thrust w as taken up by

cast i ron L shaped plates firmly bolted together Thi s arrangement common at
- -
.
,

present i s shown i n Fi g 1 88 I t gi ves the shaft support of the furnace 4 5

,
. .
-

by 1 00 i n at tuyeres and 84 by 1 44 i n at throat wi th a hei ght of 2 0 ft

. . .

1 0 in of the former Ger mani a Lead W orks of Sal t Lake Ci ty desi gned by
.
, ,

H V Croll
. .
l
H eavy b ri ck arches carryi ng th e shaf t are sprung b et ween
.

sui table sk ewback s attach ed t o the col um -

ns and connected bv 1 16 and 2 i n -
.

tensi o n rods .

Th e walls o m odern bri ck furnaces are made very thi ck at the bo tto m
r
,

3 5
2 i n i n co m p ar i so n w i t
. h t ho se of ea rli er d a t e 1 7 i n an d d ec r e ase i n ,
.
,
.

thi ckness tow ar d the f eed floor ei th er unifor m ly or i n steps It i s beli eved that -
.

thi s t hi ck ness of wall causes a consi derable savi ng i n fuel .

The shaf t Fi g 1 73 i s braced wi th ti e rods d secured i n co m

' ’
,
.
,er i ro ns c -

, ,
-

,
.

In m ore recent furnaces the shaft i s sec ured by hori zo ntal I beams whi ch are -

backed by i ron pl ates and ti ed by rods and t urn buckles -

.

B ri ck shafts have the di sadvantage that the bri ck work i s attack ed by the
comp onents of the charge whi ch usually adhere to i t formaccreti ons tro ubleso me ,

to rem ove and penetrate i nto i t and weaken i t Th us there are frequently
, ,
.

found i n the unal tered bri ckwork vei nl ets of galena ; the bri ck s are more or less
2

corroded ; agai n they may have been completely changed by the charges ,
“ It .

i s true t hat a bri ck wall conserves heat bet ter than a water j ack et The am ount -
.

of heat lo st through j acketi ng the upper par t of the furnace i s large Th us .

,

WmW rai th fo und that wi th th e blast furnaces at Tooele Fi gs 1 74 and 1 75 the

.
‘
,
.
,

upper j ac kets of a furnace requi red 1 59 gal water p er m i n wh en enteri ng at . .

,

and leavi ng at 1 6 F ; thi s correspo nds to 60 1 1 8 1i ters of w ater at 68 C

°
. . .

°
rai sed 6 3 C 3 700 Cal Never theless the advantages whi ch j ack ets ofl er
. . .
,

sm all form at i o n of accreti ons ease of th ei r r em oval as they do not attack th e ,

walls and espec i ally the short ti me req ui red for blowi ng out and blowi ng i n agai n
,

a f urnac e that i s out of order have app ar ently m ore than balanced the di sad ,

vantages and have been the cause of thei r replaci ng bri ckwork Accordi ng to
, .

“
W rai th at Too ele the average ti me occ upi ed i n barri ng down and repai ri ng bri ck
, ,

work wi th a do uble ti er of j ack ets i s days wi th a si ngle ti er days ; the ,

red uc ti o n i n tonnage p er year due to lost ti me i s tons wi th a do ubl e ,

and tons w i th a si ngle ti er of j ack ets .

An early exam ple of a water j acket shaft i s that of the Zeehan and D undas -

E ng . Mi n J . .
, 1 89 8, La w 64 1 ,
.

Stulzer, Z t p kt Geol , 1 908 , m XVI , n o

“
.

m 39
. . .

M assi a, Oest Z t B erg 3 12 q . . . 1 91 8, Lv , 1 .

Pri vate notes , July, 1 9 1 6

4
.

5
Pri vate co mmuni cati on , October, 1 9 1 6.
15
226 ME TALL URGY OF LEAD

W ork s Tasm ani a

,
whi ch had wro ught i ron upper and cast i ron lower j ackets
,
- -
.

In all furnaces there i s i n use a double ti er of j acket s the lower enclosi ng the ,

sm el ti ng zone the upper th e shaft proper ,

The upper j ack ets usually do no t .

extend to the feed floor Fi gs 1 84 and 1 85 but ter m i nate fro m5 to 1 0 ft bel ow
-

,
.
, .

to m ak e roo mfor b ri ckwork alone Fi gs 1 80 and 1 8 1 ; or for bri ckwork pro t ect ed ,
.

by cast i ron plates Fi gs 1 74 and 1 75 to take up th e i mpact of the charges th at

-

,
.
,

are fed m echani cally ; or for cast i ron plates alo ne Fi gs 1 76 and 1 77 -

,
. .

—
The si d e j ackets are 2 5 3 ft wi de and abo ut
-
ft long th ei r num ber de . . .
,

pendi ng upon the length of the furnace In the furnace of Tooele Fi g 1 75 .

, .
,

t here are tw o si d e j ack et s 5 ft lo ng and tw o 2 ft 6 i a ; th ey are 2 1 and 2 4 i n

-
.
,
. . .

wi de The ends of a furnace usuall y have each two ver ti cal j ack ets Si de
. .

and end j ack ets are usually suspended by hangers fro m I b eam s (m ant l e -

frame) whi ch support th e superstructure of the furnace and the chargi ng flo or .

They are joi ned by l ugs and bol ts and are braced by hori zontal I beams ,
-

whi ch are bol ted together at the ends wi th connecti on angles The j ack et .

plates usual ly of flanged steel are joi ned by ri veti ng or pref erably by wel di ng
, , .

The i nner pl ates are of heavi er m ateri al i n , t han t he outer i a to ,

.
, .
,

counterac t warpi ng or bucldi ng The outer plates have ri veted to themdi s

’
.

tance pi eces whi ch support the i nner ; the latter thus cfler a sm
-
oo th and st rong
surface to the desc endi ng charge and resi st corrosi on b ett er than t he ol der

plates wi th their stay bolts The i nner plates are m

,

ore readi ly corroded t han -

.

t he o uter 8
The water spac e i s 4 5 5 i n ; the water i nlets are near the bo ttom
. s -
. .
-

and the outlets near the t ops ; the i nlet pi pes are provi d ed wi th elbo w s so that -

the water m ay be d eli vered i n a downward di r ec ti o n and not i m pi nge upon the
i nner plates .

1 09 Feeding and Gas w

. i thdraw ing Openi ngs — All lead f urnaces have -
.

an open t hroat as the i ssui ng gases have no fuel val ue ,

The i dea of closi ng .

the thro at wi th cup and co ne as wi th the i ron b last furnace and feedi ng , ,

mechani cally was suggested some 30 years ago by H ahn and tri ed at a later“
date but has not been successful as the heat crep t up and gave a hot top
0
, , .

Open top furnaces used to be fed al m

-
ost excl usi v ely by hand and sti ll are t o ,

som e extent Wi th the i ncrease of size of furnaces and the use of blast roasted
.

ore the t o nnages of furnaces have so i ncreased that hand feedi ng has been -

largely replaced by m ech ani cal feedi ng Whi chever method m ay be used .
,

the charge has to be fed ei ther fromthe top or the si des Wi th top feedi ng .
-

the gases m ay be wi thdrawn fro mthe si d e or the top ; wi th si de feedi ng they -

are i nvari ably wi thdrawn fro mthe top .

In Fi g 1 73 the rec tangular feed openi ng m i n the top plate, w is 2 0 2 4 —

’ ’ - -
.
, , ,

i n wi de and 60 i n long or m
. ay extend to the ends of the furnace . The charge ,
.

1
Beardsley, Tr A I . . . M . E .
, 1 88 2 8 3 , xxx, 575
-
.

Edi tor, E ng M i n J , 1 89 3, LVI , 52 3 . . . .

Ri ce, Strai gh teni ng W arp ed Jack ets, E ng Mi n J , 1 9 1 1 , x 01 , 653

m m8 6
. . . .

Lee, Tr A I M E , 1 90 7, xxxv , 8 77 ; di scussi on, p 8 78, and 1 908,

. . . . . m .
, 0 .

D wi ght , Tr A I . . . M . E .
, 1 90 2 , xxx u, 3 53.
5
Mi n Res U S . . . 88 2 , p 34 3
.
,
1 . .

D wi ght ,
Tr . A I M E , 1 90 2 ,
. . . . xxx n , 369 .
228 ME TALLURGY OF LE A D

l r the coarse toward the center as i t gli des down the gri zzly A si m
and ate ilar .

d evi ce has been patented by D wi ght 1

.

Practi cal experi ence has shown that furnaces fed by hand fro mthe top do
not work as well as when fed fromthe si des D wi gh t calls attenti o n t o the fact
’
.

t hat on a shovel contai ni ng fine and coarse ,

ore the fine par ts predo m i nate on th e bo ttom ,

and the center and th e coar se on the t op and ,

si d es If the contents are thrown fro mthe .

shovel the coar se trav els faster th an the ,

fine In feedi ng a furnace from the top .

,

Fi g 1 90 the coarse wi ll prevai l along the .

,

si des and the fine alo ng the center ; in ,

feedi ng fromthe si de Fi g 1 9 1 the reverse ,

.
,

i s the case In a blast f urnace th e ascending .

gases meet less resi stance near the furnace

— Blast furnace top fed
Frc x9c . .

walls than near the center and therefore

,
-
,
,
by ha nd
have a tendency to r ush up at the si des In
.

doi ng thi s they overheat the charge near the si des and do not exer t the neces
,

sary th erm al and chem i cal eflect upo n the central porti on of the charge .

Furth er th e hi gh v eloci ty and t em

,
perature of the gases at the si des causes an
excessi ve am ount of dust and f ume to be formed H ence si de feedi ng by .
,
-

hand i s preferable to top feedi ng -

.

As to the w i th drawal of gases th ere ,

canno t be an even ascent thro ugh the

charge i f the do wncom, er wi th i ts suc

ti on i s placed at one end of th e furnace

as i n Fi gs 1 72 and 1 73 ; i n addi ti o n t o
.

thi s the gases b ei ng drawn 05 from

, ,

the top of th e charge carry 03 all the ,

dust they have entrai ned .

In a hoo ded furnac e Fi g 1 9 1 the ,

.
,

gases pass 03 more evenly from the

t op of the charge and thei r veloci ty i s ,

retarded by ai r enteri ng the feed door s; -

thi s causes th em to drop d ust whi ch ,

falls back onto the charge Si de feed .

-

i ng i s therefore preferable to top feed -

i ng as regards the asc ent of the gas

current O bj ec ti on i s made that i t
.

req ui res a stronger Chi mneY draft b‘n Fro 1 9 1 — Blast furnace si de fed by hand
’

'
-
a . .
-

, ,

thi s i s not necessari ly the case as i n ,

regular work the sli di ng doors of the feed openi ng are k ep t close to the si ll -
,

leavi ng j ust enough space to permi t an even di st ri buti on of the charge Only .

1 U S Patent N o 9 59 4 84 , M ay 3 1 ,
. . . 1 91 0 .

Tr A I M E , 1 90 2 , xxxn, 367
. . . . . .
 S M E LTI N G LE AD ORE S I N TH E BLAS T F URN ACE
’

in barri ng down wall accreti ons are the doo rs rai sed full y There i s left then
-
.

an open space 8 ft hi gh whi ch greatly favors the work Wi th a top feed

,
.
,
.
-

th e top plates have to be r em

-
oved before work of thi s character can be carri ed
o ut wi th any d egree of success .

Ano ther devi ce for top f eedi ng of charge is the Pfort cur tai n or thi m ble -

wh i ch was used first wi th i ro n blast furnaces in wi th lead f urnaces

at La Pi se Franc e b efor e ,
and at Frei berg Saxony abo ut
, In 1 883 , ,

FIGS . 1 92 and 1 93 — Blast

. furnace Omaha and Grant Smelti ng and
,
Refini ng Co .
,

D enver Colo 1 883 , .

, .

t h e furnac es of the O maha and Grant Works Denver Fi g were , ,

. 1 9 2 1 93,
-

p rov i d e d w i th t hi s c ur ta i n I t co n si sts of a n i ro n s h e.ll w su sp en de d fro m th e t o p , ,

p l at es i n su ch a w a y a s t o l eav e ro om b et w e en i t an d th e w a ll s for th e g a se s wh i ch ,

p a ss o fl t hro u gh th e fl u e 0 i n t o th e d u st ch a m b e r,
T h e ch a
,
rg e fi ll s t he i ns i de .

of the curtai n up to the feed floor Thi s arrangement i s very sati sfac tory a -
.
s

r egards th e i ntrod uc ti on of the charges and the absence of smoke on the feed
fl oor Its drawbacks however are so great th at i t has b een di scarded
.
, ,
T he .

charge Fi g 1 94 i n i ts descent to the

,
.
,

do wncom er separat es m ore or less i nto

coarse and fine ; the coarse roll s toward

th e wall whi le the fine rem ai ns at th e

center . Thi s autom ati c sor ti ng i s si m i lar

t o t hat taki ng place i n the q uar teri ng
method of sampli ng when for the purpose ,

of m i xi ng the ore i s coned ; the coarse

, —
Ero Pfort curtai n
co ll ects t oward the ri m of the co ne and
94 . 1 . .

t h e fine rem ai ns i n t he c enter Tw o o th er di sadvantages are that the m . an ,

ner i n whi ch the charge si nk s can be ob served only by allowi ng i t to drop

below the thi m ble; and t hat for b arri ng down wall accreti ons the thi m ble has to -

“
Percy, J , Iron and St eel , M urray,
”
London 1 864 , 6
.
p 4 9
m
. .
,

Grti ner, Arm Mi n , 1 868, x , 3 73 . . .

Pil tz furnace Berg H ar

le . . m 869 , xxrx , plate Ix
» . Z 1 .

Frost Eng . Mi n J .
, 1 883, xxxv, 1 63 .
230 ME TALLURG Y OF LEAD

be removed The wi thdrawal of gases fromthe end of the furnace has been
.

taken up above The areas of ore and gas spaces are gi ven i n Table 54
.
-
.

Ano th er m ethod of top feedi ng i s by m eans of th e Darby tube a pipe -

suspended i n the center of the furnace for the w i thdrawal of th e gases around , ,

whi ch the charge i s fed Thi s devi ce used wi th the i ron blast furna ce about . ,

18 was appli ed i n th e H arz Mountai ns i n ci rc ular lead blas t furnaces about

2 0 years later and i s i n Oper ati o n wi th several oblo ng Co nti nenta l E uropean
’

furnaces e g at H oboken les Anvers Belgi um; Monteponi Sardi ni a; in

,
. .
,
a ‘ - -

, ,

“
Aust rali a wi th th e Port Pi ri e furnaces and i n the Uni ted States at the Selby
Lead Works Selby Cal , , .

Food Fl oor Fee s Fl oo r

Fros . 1 9 5 and 1 96 — Blast urnace, Sulp hi de Corporati on, Boolaroo, N

. f . S . W .

The furnac es Sulphi de Corporati on, Boolaroo , N S W , of the . . . and the

m
Selby S el ti ng and Lead Co , Selby , Cal , ay serve as exa fl es . . m m .

The f urnace of the Sulphi de Corporati on, Fi gs 1 9 5 and 1 96, wi th . at hroat

1 . by 1 0 ft 3 i n = 1 71 68 sq ft has an o blong thi mble 1 2 by 5 ft
6 ft 9 i n . . . . . .
, ,
.

60 sq ft for th e wi thdrawal of gases whi ch extends 5 ft 1 0 i n i nto the

. .
, , . .

furnace and leaves a feedi ng space 2 ft 1 56 i n wi de at the si des and the ends . . .

The top of the furnace i s enlarged to m ake roomfor tracks on whi ch arri ve

bo tto mdi scharge feed cars

- -
.

B erg H a . mm Z e n . .
, 1 858, xvn, 2 63 ; 1 3 79 862 , xx l , .

Oest Z t Berg B atten

. . . 1 8 76, xxx v, 3 2 0 ; B erg H are . m . Z .
, 1 8 76, xxxv, 336 .

Ann: M i n Belg , 1 90 1 , . VI , 2 6 2 ; 1 9 1 3 , xvrn , 500 .

Oerst Zt B erg H attenw, 1 905, 4 55 ; E ng Mi n J 1 905, D oor, 78 1

m5
. . . . . . .
, .

Tr Austral I nst
. . . Mi n . Eng , . 1 907, x11 , 1 ; Eng . Mi n . J .
,
1
90 7, Ixxx
, 1 7 .
232 M E TALL URGY OF LEAD

l eaves a feed space along the si des of 1 3 ft by 1 ft 8 i n = 2 1 66 sq ft The

-
. . . . . .

furnace i s hand fed ; fuel and charges are rai sed fro mthe furnace to t he feed
-

floor by m eans of a ver ti cal elevator dri ven el ec t ri call y Ot her d etai ls are .

tak en up later .

In experi m enti ng wi th thi s formof feed at Murray Utah i t w as fo und that , ,

the charge b etw een t hi m ble and throat so meti mes became h ung up At .

Port Pi ri e the throat of the furnac e 6 ft 1 0 i n wi de has a thi m ble 4 ft w i de ,

. .
, .

on the feed floor whi ch extends 3 ft i nto the furnace and i s co ntrac ted at the
-
.

bo ttomto a wi dth of 2 ft 6 i n ; i t thus corr ec ts all possi ble danger of the charge . .

becom i ng wedged fast betw een si d e wall and thi m ble -

.

The advantages of thi s devi ce are th at i t i s sui ted for hand and m
,

echani cal

feedi ng that the center of the charge i s loo sened that the gases are wi thdrawn
, ,

along th e c enter li ne of the f urnac e that the si nki ng of the charge can be -

followed and that shaki ng up of the charge by means of the steel bar to correct
,

hangi ng i s readi ly accomp li shed as well as the barri ng down of wall accreti ons ,
-
.

Thi s d evi ce therefore prom i ses well .

TAB LE 54 — Pour Anu . s or FURN ACE S wrrn Pronr Cunru n AND Dw r Tuna
' '

Area t h ro at sq ft
s—
. .

Area op enrng sq ft
m
. .

Area ccd o ng sq ft
gz
-
.
.

Dep t h of tu . ft
Rati o gas o p eni ng : feed o p eni ng
.

- -

( 0 Does ext end to ends of furnace ( 6) Does no t ex tend to ends of furnace

m m m
. .

eferences : ( 1 ) A nn M i n 1 86 8 x 3 73 Bar H ar a n Z 1 86 xxv p late 1x (3)

7
3
2 1
E ng M m J
. .
, . . . . .
, . . .

. 1 883 xxxv 1 63
. . .( 4 ) Ke rl G rundrrss der . et all h utte nk unde el i x Lei p si c
. . . . 1 88 1 . 3 0 ( 5)
( 6) Tr A ustral I nst M i n E ng 1 907 x " 1
. , .

Pri vat e notes .

( 7 ) A nn M i n Bel g 1 9 01 V1
. . . . . , . . . . . . . . . 2 62 .

1 1 0 H earth . i th Arents Auto ati c or S iphon Tap — The hearth , or the w m .

cr uci ble wi th i ts enclosi ng bri ck and i ron work , extends fro the fo undati on -

m
to the mof the j ack t It i s er c t d n th b d plate y i n Fi g 7
bo tto e s . e e o e e -

,
’
1 2 .

omti m has an angl i ron i mwhi ch may nclo e th t p of th f unda

.

Thi s s e es e -
r e s e o e o

ti on or th bo ttomco ur e of bri ck ; i t m
e ay ven nclo the i ron ca i ng whi ch s e e se s

strength ens th e d w plate i s a strai gh t pi ec e of soft

si e
-
alls . Usually the bed -

steel lai d level i n c ement upon the fo und at i o n .

On the bed plate i s placed the i ron casi ng whi ch i s to encl ose and s t reng then
-

the walls of th e cruci b le as these h ave to resi st th e pressur e of the lead charge , , ,

and j ack ets and the thr ust due to expansi o n , Form erly t he casi ng co nsi sted .

’
of cast i ron plates (cruci ble casti ngs h Fi gs 1 72 andr73) strengthened by ri bs r
'

- -
.
, , ,

and fastened together at t he beveled corners by ti e rod s b These casti ngs

’
-

, ,

even when thi ck of ten developed crack s caused by an uneven di stri b uti on of ,

pressure They were cl umsy wi th sm

. all f ur nac es and b ecam e im p o ssi ble when ,

these were m ad e larger .

 S M ELTI N G LE AD ORE S I N TH E BLAS T F URN A CE
’

At present therefore the casi ng i s made of heavy boi ler plate strengthened -

by I beams or rai ls Fi gs 1 80 and 1 8 1 whi ch are ti ed at the co mers by bolts or

-

, .
,

connec ti ng pi eces In several i nstances as at Trai l ( Fi g Mi d vale Pi tts

.
,
.
,

b urgh etc the outer hearth wall has been made oval and enclosed wi th
,
.
,
-

boi l er plate -
i n thi ck ; thi s i s sufi ci ently strong and does away wi th the .

c umb erso m e I b eam s or r ails -

.

The cruci ble i s i nternal that i s i t form s the conti nuati on of the shaf t and , ,

does not extend beyond i t Slag and m at te are tapped at the top of the cr uci bl e .

t hro ugh tap hole mFi g 1 73 i n tappi ng j acket n at the end of the f urnace and
-

, , .
,
-

, , ,

run out over cas t i ron slag spo ut a Lead i s recovered at the si de th rough cast
- -

, .

i ro n spout a placed a li ttle hi gher than the slag spout ( see below)
'
-
.
, ,

Fi gs 1 72 and 1 73 show tw . o slag and t w o lead spouts Thi s arrangem ent -

.

has becom e ob solete Tappi ng frombo th ends has been carri ed on to correc t .

t h e for m ati o n of a crust at the back of a furnace w

.

i th a si ngle tap where i t ,

us ually begi ns and grows toward the front Tw o taps were f easi ble wi th sm all .

f urnaces l
Wi th the large uni ts common at present i t i s preferable for the
.
,

handli ng bo th of charge and of prod uc ts that one end of the f urnace face the
d um p and thi s renders double tappi ng i m
,
possi ble There are o ther ways for .

counterac ti ng the form ati on of b ack cr usts H avi ng tw o lead wells i s a waste .
-

of h ea t ; w hen one becomes cl ogged the other wi ll soon follow sui t ,

.

A cruci ble par tly i nternal and par tly ex ternal has b een gi ven up The .

M athewso n fore hearth was i n operati on for m

’
any years at Pueblo Colo -

, .

The heart h walls and bo tt omof cr uci bl e are of the b est grade of fire bri ck -
.

Form erly they rest ed on the bed pl ate Fi g 1 73 At present a layer of gro und ,
. .

bri ck and clay i n the proporti on of 3 2 ( Fi gs 1 74 and 1 7 or crushed quartz .

( Fi gs 1 80 and 1 8 1 ) i s beaten down firm

. ly to the formof an i nverted arch on ,

whi ch the bri cks are placed ; thi s layer allows for expansi on of bri ckwork In .

bui l di ng the si de walls i t i s better not to place the bri cks i n di rec t contact wi th
-

the casi ng especi ally if t hi s i s cast i ron but to leave open a sm

,
all sp ace of about ,

23 6 i n a nd fill t
. hi,
s by ta m pi ng w i t h br asq u e eq ual vol um e s of cr ush ed cok e ,

and clay Wh en the bri ckwork expands upon heati ng i t wi ll pack the
.
,

br asq ue more ti ghtly and reli eve the casi ng frompart of the st rai n In the .

tw o top co urses of the si de and end wall s the fire bri ck are frequentl y replac ed -

by magnesi te bri ck as thi s m ateri al resi sts the corrosi ve ac ti on of m atte m uch ,

bet ter than fire bri ck In case magnesi te bri ck are not avai l able fire bri ck -
.
,
-

h contai ni ng m
,
uch Ala are used Th us t w o ki nd s of Laclede b ri ck fro mSt . .

Lo ui s Mo are freq uent ly found the so called 70 p er cent w

,
.
,
i th A130; ,
- -
.

F6 20; 6 Si 02 30 and the 60 p er c ent w

,
i th M203 Pegos SIG: 38
,
-
.
, .

At Trai l B C Fi gs 1 76 and 1 77 a 1 2 i n layer of concrete encloses the fire

, . .
,
.
,
-
.

bri ck walls .

In order to prevent any lead fro ml eaki ng out at the front thro ugh the bri ck
work and bei ng carri ed ofl wi th the slag a water block wi th trough shaped
, ,
- -

slag g utt er i s of ten b ui l t i nt o t he bri ckwork

-
If any labor has to be perform ed .

1
H enri ch , Tr A I M E , 1 89 5, xxv, 96 . . . . . .

’
See p receding edi t i on, page 2 3 7 .
234 ME TALL URGY OF LEAD ’

i n the cruci ble a free worki ng openi ng i s easi ly m

,
ade by rem ovi ng the tappi ng
j acket and water block -
.

The depth of the cruci ble Table 51 shows a range of from2 0 to 30 i n ; i t i s , .

usually nearer the latter than the for m er figure The length and wi dth at th e .

top are the sam e as the di stances b et ween the j ackets In order to red uce the .

am o unt of lead necessary to fill the cruci ble whi ch am —

ounts to 2 0 40 tons the , ,

bri ck are frequently stepped down fromthe si des and ends to the bottom gi vi ng ,

the cruci ble the for mof a t runcated pyram id A deci d ed red uc ti on of the cross .

sec ti onal area fro m front to back i s sho w n i n Fi g 1 75 . .

The Arents tap whi ch form

l
s part of the si de w
,
all consi sts of an i ncli ned -

channel d Fi g 1 73 from4 by 4 to 8 by 1 2 i n i n cross secti on whi ch runs from

, ,
.
,
.
-

the bo tt omof the cr uci ble si de wall i nsi de to the top on the o utsi de and i s h er e -

enlarged i nto a di sh shaped basi n the lead well c Fi g 1 73 -

The tap i s placed ,
-

, , . .

i n the m i ddl e of one of th e si des or preferably nearer the front as i t i s t hen , ,

more accessi ble Whi l e the furnace i s runni ng the cruci ble remai ns full of
.
,

lead or nearly so ; the lead i n the well stands hi gher on acco unt of the wei gh t
,

of the charge and the pressure of the blast In the early furnaces Fi g 1 73 .
, .
,

run wi th low blast pressures the top of the basi n w -

as on a level w i th t hat of
,

the cr uci ble Wi th m odern furnaces havi ng blast pressures of fro m30 to 40
.
-

oz . the basi n has been plac ed upon the cr uci ble w

,
all ( Fi gs 1 74 1 75 1 80 1 83) -
.
, , ,

i n order to rai se the level of di scharge and t hereby to prevent the lead i n the ,

cruci ble fromsinki ng too far below the level of the tuyeres as thi s favors t he ,

cooli ng of spei ss matte and mushy materi al and thereby the form
, ,
ati o n of ,

crusts The di scharge of the basi n li es from4 to 1 0 i n above the top of the
. .

cruci ble The hei ght req ui red of the basi n to keep the lead i n the cruci ble
.

at t he top of th e hear th can be calc ulated

“ but act ual experi ence w i ll m odi fy ,

the re s ul t ; i n fac t m ost furnace m en cl ose up th e di sch arge peri odi cally to force
,
-

the lead i n the cruci ble to ri se unti l som e runs out wi th the slag and th us ,

i nsure a com plete outflow of spei ss m atte and m ush w hen the furnace i s tapped , , ,

dry Wi th charges runni ng hi gh i n lead say 30 p er cent the lead i s allowed to

.
,
.
,

ov erflow i nto a sui table recei ver ; wi t h the usual 1 3 p er c ent i n sil ver lea d .
-

sm el ti ng i t i s tapp ed p eri odi call y

, .

The ad vantages of the si phon tap are so great that i t has been adop t ed
everywhere unless co ndi ti ons forbid i ts use Wi th the older f urnaces lea d and .

matte were tapped together fromthe bottomof the cr uci ble i nto a shallow basi n ,

and the tap hol e w as pl ugged as soon as slag began to appear

-
A T i ron w i th .
-

eye w as placed up si d e down i n the m ol ten mass ; the matte soon soli dified and
-

was rai sed by means of a chai n or wi re rope; th e adheri ng lead was allowed to
dri p ofl the cak e of m,
atte m oved to one si de and the lead ladl ed i nto molds .

I nto the cruci ble of the furnace freed fro mlead and m atte but still retai ni ng ,

som e cok e th ere dropp ed an eq ui valent am

, ount of half melted charge whi ch -

had to be rai sed grad ually by fresh lead and m at te Wh en thi s was the case .
,

tappi ng began agai n These half m el ted m asses had a chance to adh ere
.
-

H ahn E i lers Ray ond, Tr A I

- -
m . . . M . E . 8 7 1 72 ,
, 1 -
1 , 1 08 .

von Schl i pp enbach , Meta” n E . . m , 1 9 1 4 , xx, 652 .

236 ME TALLURG Y OF LE AD

nozzles p r ot r ud ed J W illi a m
i nto the furnace
s b u i l t . Do uglas l
says that .

near Dronth ei m N orway i n 1 852 sec ti onal water j ack et f urnaces co nsi sti ng
, ,
-

”
of a ci rcle of long narrow water backs perforated by tuyere holes , About -

,
.

t he year 1 865 the sam e J W i lli am s erec ted a num ber of water j ack et blast .
-

furnaces at H o ugh ton Lake Superi or Accordi ng to Arents H askell b ui lt ” .

, ,

i n 1 865 a water j acket furnace i n Cali forni a Kerl i n descri bi ng th e i m

a -
.
,

p ro ve m en ts m a d e i n sm el t i ng i n t he H ar z M o u nta i n s r e cord s th e i n t ro d u c ti o n ,
‘

i n 1 864 of water block s to cool the hear th and to serve as a suppor t for t he -

water cooled tuyere nozzles, but these had been used i n refinery furnaces
-

for a very long ti me and are not to be confounded wi th water j ack ets
‘
,
-
.

The latter were not i n use i n the H arz M o untai ns .

Spray j ackets were used at La Pi se, France as early as

-

Fro mthe statem ent of Daggett i t appears that be erec ted the first cast i ron
‘ -

j acket at the Wi nnamuck lead smeltery i n 1 872 .

Cast i ron J ackets — The ori gi nal cr ude cast i ron j ackets were i m
-
proved
.
-

here and there unti l they assumed the present formgi ven themby E i lers and
Stei tz 7
In recent y ears soft steel j ack ets have b egun to take the place of t he
.
-

cast i ron; and app arently wi ll replace thementi rely i n spi te of the fac t t hat
they cost m ore and that when worn they formscrap wher eas old cast i ro n has .
,

metal val ue especi ally i n the nei ghborhood of a fo undry Usually old j ackets .

are brok en up and used as p r eci pi tati ng i ro n i n th e ch arge Il es no ted t hat

8
.

corroded cast i ron j ackets as well as matte po ts showed values i n Ag; th us

- -

a corrod ed m atte p ot freed fro m all adh eri ng m ateri al assayed 35 oz Ag

-
.

p er t on a n d ca st i
,
ro n j ack ets gav e si mi l ar val ue s S t ee l
-
j ack ets l a st l o n g e r .

th an do cast i ron are easi ly repai r ed by a blacksm -

i th are li gh ter and hence
’
, ,

readi ly removed fro m the furnace and p ut agai n i n place Croll gi ves a ‘°
.

li fe record of 1 4 m
-
o nths for ca st i ron j ackets of the Globe Works of D enver -

Colo but t hi s i s very excepti onal ; a li fe of 3 m

.
,
onths i s nearer the average .

Cas t i ron j ack ets are less q ui ckly corroded by sal t water than are tho se of soft
-

steel . Crack s i n a cast i ron j acket can be repai red at the works by brazi ng -

wi th a m i xture of copper oxi de and borax after holes have been bored at the
ll

ends of a cr ack to pr event i ts extendi ng

u or by cutti ng a dove tai l and caulki ng -

wi th copper ; but the result i s not always successful .

Furnace m en who have exchang ed cast i ron j ackets whi l e a furnace i s run -

ni ng rem em b er the wei ght .

Mineral Resources of th e Uni ted States, 1 88 2 , p 2 68

wt nm Z
. .

Berg H . e . .
, 1 866 , xxv, 316 .

Op ci t . .
, 1 86 7, xxvr, 6 and 47 .

Percy, Metallurgy of Iron and S teel M urray London 1 864 pp ,

”
, , ,
.
584 and 62 5 .

Gruner, Ann M i n 1 86 2 x m 364 . .

, , ,
.

E ng M i n J 1 885, XL 3 1 6 ; Mi n I nd , 1 905 x r
. v 4 09 draw
. i ng ,
. .
, , ,
.

Tr A I M E 1 9 1 5
.
735 . . . .
, ,
.

Pri vate notes, 89 6 1

m m 344
.

m
Bro i de, E ng Mi n J , . . . 1 9 7,
0 ,
.

Op ci t , 1 89 8, 639 m .

moo n
. .
,

Pi ch p rocess, op . ci t. , 1 90 6, ,
2 28 .

Anon, op ci t . 1 890, 575 .

 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN ACE

Cast i ron j ack ets, f, Fi gs 1 72 and 1 73, are fro 3 to 5 ft hi gh , have walls
-
. m .

.
—
i n thi ck , and a water space of 4 % 6 i n ; the si de j ack ets, f, have a bo sh , -
.
-

the end j ack ets , e, do not-

The si de j ackets are ver ti cal for a di stance of abo ut .
-

1 8 i n and th en spr ea d o utward to for

. a bo sh of abo ut 2 ft i n hei gh t wi th a m .

flare of 2 4 i n p er ft A furnace has usuall y three ki nds of j ackets, two, e, at

— . .

the ends each half the wi dth of the furnace and one f about 2 0 i n w i de at the , , , .
,

si des . Each j ack et has i ts ow n water fee der whi ch begi ns 8 or 1 0 i n above the -

,
.

center of the tuyere and extends 3 or 4 i n above the top of the j acket where .
,

i t i s abo ut 4 i n wi de Thi s i nsures com plete filli ng of the j acket The feeder
. . .

was always cast i n one pi ece wi th the j acket ; later i t was frequently a separate
casti ng fastened wi th screws or bol ts and m
,
ad e water ti gh t w i th a gasket -
.

Cooli ng water i s adm -

i tted thro ugh the water feed pi pe h t o whi ch i s attach ed a -

, ,

hose to co nduct downward the cold water so that the larger part may pass by
the ri si ng war m water w hi ch i s di scharged through overflow pi pe i deli veri ng , ,

i nto w ater t ro ugh j wh i ch em p ti es i nto a waste pi pe Jackets have hand

-

, ,
-
.

holes to remove scale and mud ; they are joi ned top and bo ttomby bol ts y , ,

passi ng t hro ugh lugs cast i n the j ackets The t uyere openi ng 3 4 i n i n di — -
.
.
,

am et er i s i n the center of the j ack et 1 0 1 2 i n above the bo tt om The open

,
—
, . .

space bet ween the t0p s of j ack ets and shaf t w alls i s fil led wi th a co ur se of fire -

bri ck As thi s m
. ateri al i s freq uently sl agged wherever sm el ti ng t akes place

above th e j ack ets tw o rows of water cool ed pi p es are i m

,
bedded i n the bri ck -

work ; i n so me i nstances water cooled i ron boxes have been suspended fromthe
,

ca pi t als of th e i ro n col um ns .

B esi de t he regular j ack et s there i s used a t appi ng j ack et n Fi g 1 73 Thi s -

, , . .

is a w a ter cooled casti ng e g 2 6 by 1 4 i n and 3 5 i n d eep m

-
ade of cast i ron
, . .
,
. . .
,

or cast steel whi ch has 6 5 i n above i ts lower edge a coni cal tap hole
,
in
. .
-
.

i n di a m eter and 1 i n deep The lower edge of the j ack ets i s plac ed 4 i n beneath
. . .

the upper edge of th e cr uci bl e casi ng to prevent at the front all l eakage of l ead -

from the cr uci ble whi ch i s o therwi se di fli cult to stop A cast i ron tappi ng
,
.
-

j ack et may last onl y 7 8 days wi th large matte fall whereas a j acket made
— -

of a water cooled coi l of i ron pi pe i mb edded in copper lasts 70 80 days

- — .

Tap hol es used to be m

-
ade 1 5 i n i n di am eter ; i n Fi g 1 73 th e si z e i s 2 5 i n . . . . .

Som e f urnace m en m ai ntai n t hat the hol e o ugh t t o be 4 i n i n di am

-
eter so as to .

p ermi t fl ushi ng out mush whi ch i s not tak en up by slag or matte If thi s .

mush accumulates i t may close up the first and even the second tuyeres near
,

the front The 4 i n tap hole i s usually opened only i n par t but i s very
.
-
.
-

servi c ea bl e w hen occasi ons demand a thorough cl eansi ng .

—
S ofb steel J aci nta The general feat ures of the steel j ack ets enclosi ng th e
sm el t i ng zo ne are the sam e as those for m i ng the shaft walls They are usually -
.

hi gher than those of cast i ro n; th us Fi gs 1 74 and 1 75 show j ackets 6 ft hi gh -

. .
,

and Fi gs 1 76 and 1 77 1 80 and 1 8 1 1 84 and 1 85 j ackets that are 6 ft 6 i n

.
, , ,
. .

hi gh whereas wi th cast i ron the usual hei ght does not exceed 4 ft The wi dth
,
-
.

of the lower steel j ack et i s the same as that of the upper as are the water ,

space and the thi ckness of plate One charac teri sti c not shown i n the draw .
,

i ngs is that the botto mof a j acket i s not ho ri zontal but i ncli ned o utward so
, ,
238 M E TALLURGY OF LEAD

that mud c l di stri b uted along the bo ttom but collect i n a

and s a e are not ,

t ro ugh for m ed by the i ncli ned bo tto mand the o uter sheet whenc e i t i s re ,

moved peri odi cally through hand holes The lower j ackets are j oi ned and -
.

held i n place i n the sam e m anner as are the upper Both have w ater i nl ets .
-

and o utl et s near bo t to mand t op The usual formof outl et i s shown i n th e .

H olthofi j ack et Fi g 1 99 i n whi ch stress i s lai d upon gi vi ng the c urvat ures

,
.
, ,

A and B at cor ner s large radi i espec i ally on the fire , ,

sh eet so th at they take up rea di ly the exp ansi on caused

by heat i ng .

The lower steel jackets ei ther have a bosh Fi gs 1 74 ,

.
,

1 77 1 80 as do the cast i ron Fi g 1 73 or not Fi g 1 84 , , , .

, ,
. .

The form er i s m ore co mmon ; wi th charges made up mostly

of blast roasted m ateri al th e bo sh i s lo si ng i ts form er

im portance .

The cooli ng water for the j ack ets i s drawn fro m a -

mai n tank placed some di stance above the water i nlets of -

th e j ackets i n order th at the water m ay have th e head

necessary to force thro ugh the pi pes th e ext ra am o unt o f

water need ed over the norm al wh en th e furnace i s blown ,

i n or out The posi ti ons of the m ai n and branch pi pe . s are

shown i n t he draw i ngs The am ounts of water used i n .

modern furnaces are gi ven i n Table 53 The j ackets are .

washed out at i ntervals to remove acc umulati ng mud .

Thi s i s done m ore frequently wi th the lower than th e

upper Wi th clean wat er that i s not hard the upper .
,

j ackets are washed out perhaps once a month or oftener

1 99 — H ol th ofi
.

steel j ack et
when i t beco mes necessary to bar ofl hangi ngs
.

In m any i nstanc es when th ere i s a lack of w ater th e sam ew ater i s used over ,

and ov er Thi s necessi t ates cooli ng apparatus of whi ch there exi st m

. any

form
,
1
s.

1 1 2 Tuye . res — The di am eter of tuye . re openi ng i s 4 4% i n the center i s

— -
.

p la c e d u su a lly a bo u t 1 3 i n a b o v e t h e b o t t o m of th e j a ck e t ; a n d t he
. d i st an c e

between centers i s 1 6 1 8 i n — The di am eter used to be 3 i n ; the i ncr ease t o 4 and . .

4 % i n i
. s d u e t o t h e d e s i r e of i n cr ea s i n g t h e s m el ti ng p o w e r a n d h a s b ee n m a d e ,

p o ss i bl e by t h e co m p a r a t i v e ly sm a ll a m o u n t of fi nes i n th e ch a rg es t r ea t ed a t

p r es e n t wh i ch
, a r e m a d e u p la rg e ly of bl as t ro ast ed m a t e r i a ls B efor e th e a dv en t .

of blast ro asti ng fine ores form ed a l arge par t of th e ch arge ; t hi s caused m

,
ore or
less ti ghtness and oflered a much greater resi stance to the passage of t he blast
than does the coar se ch arge prevai li ng at present .

H enri ch, Tr A I . . . M . E .
,
1 89 5, xxv, 4 3, 4 60 .

Sch mi tt , Proc S outh Afri c Assoc

. . .
—
E ng , 1 906 0 7, xx1 ,
. 2 5.

H art, E ng Mag , 1 90 7—0 8, x xx rv, 590

. . .

Roberts, 1 1 S outh Afri c Assoc E ng , 1 909 ,

. . . . x v, 33 .

Pattes on, Cass M ag , 1 909 , xxxv, 70 1 . . .

w
J ger Mi n
a , . 1 9 1 1 , x u v, 4 80, 4 9 5 .

Wheeler Balcke, -
I ron Age, 1 9 1 3, xcr, 64 6, E ng . Mi n J
. 1 9 1 3, xcv, 1 051 .
24 0 M E TALLURGY OF LEAD

ago a t l hough the general form has remai ned the sam e The older form i s .

shown i n Fi g s 1 72 and 1 73 The pi p e i s a t ub e of galvani zed i ron ; the ho ri zont al

. .

’
t ube abo ut 1 4 i n lo ng fit s i nto brass nozzle p i nser ted i nt o the t uy e
,
.
,
re hole or , ,
-

sol dered to i t ; elbo w x whi ch connec ts th e hori z ontal arm wi th t uyere

, ,

bag q has a brass ni pple w

, ,
hi ch contai ns the eye or peep hole s closed ei ther by -

, ,

a sli de or cap havi ng a glass or m i ca plate i n the center or si m ply by a wooden ,

pl ug In the center of the plug i s left a small openi ng the si ze of a pencil t o

.
, ,

be closed by a pi ece of w ood In order to keep th e blast pi pe i n i ts normal .

-

posi ti on and thus to prevent i t fro mdeli veri ng the blast upward whi ch i s i ts ,

natural tendency an i ro n band hook ed by m , eans of t wo spri ngs t o th e j ack et , ,

i s p assed aro und the elbow ; or an i ron loop i s sol dered to the i nner si d e and
booked to the j ack et .

FIGS . 2 00 to 20 2 .
— Tu e
y re p i p e
-
wi th D avi s slag e
s cape -
.

The detai ls of an i mproved formof such

wi th the Davi s slag a tuye —
r e p i pe
escap e are show n i n Fi gs 2 00 2 0 2 i n w
— hi ch a i s a cas t i ro n elbow wi th p eep
l -

,
.
,

hole I clo sed by ca p m screwed to a 4 i n wro ugh t i ro n pi pe b provi ded wi t h

, , , ,
-
.
-

, ,

Op eni ng d for th e escap e of slag and sol der ed to co ni cal brass no zz le c ent eri n g
, , , , ,

the c ast i ro n j ack et-

To the under si de of b i s ri veted flang e d wi th l ug s g
.
, , , .

They r ec ei ve i n a rec ess the p erforated di sc of sh eet i ro n f carryi ng a p i ec e o f -

, ,

pap er or sheet lead e and pressed agai nst the seat by screws It th us mak i n g
, , , ,

an ai r t i gh t joi nt
-
If slag r uns i nto the tuyere i t wi ll b ur n the p ap er or f us e
.
,

the l ead and the noi se of th e escap i ng bl ast call s the at tenti o n of the k eep er
,

to the acc i dent .

W i th the ordi nary pi p e i nserted i nto the tuyére hole a leakage of ai r ca n ,

not be prev ented even if all p ar ts are caref ully fi tted

, The lo ss i n ai r b eca me .

excessi v e wh en th e b last pr essure w as rai sed fro m1 2 to 4 8 oz and over to m

-
ee t .

the needs of w i d er and hi gh er furnaces Thi s led to the adop ti o n of a t uy ere .

box fa stened by an ai r ti gh t jo i nt to the j ack et T ransi ti o n for m

-
s such as .
,

tho se of Austi n ’
U nz i ger and ol der f o rm
,
s of t uy ere bo xes are gi ven i n th e
,
-

precedi ng edi ti o n of thi s book .

H of man E ng Mi n J 1 89 3 , W I, 396
m 39
. . . .
, ,

Mi n . S c Press,
. 1 909 , x cv , 2 .
 SMELTIN G LEAD ORES IN TH E BLAS T F UR NACE

E xa mples of modern tuyer es are tho se of E i lers, Ander son, and th e T a r ylor
E ngi neeri ng Manufact uri ng Co
and .

The Ei l er s t uyere used by m any plants of th e Am ,

eri can Sm el ti ng and Refin

i ng Co i s shown in Fi gs 2 03 and 2 04
.
,
I t co nsi sts of a cast i ro n box screwed
. .
-

t i gh tly to th e j ack et On the upper si de i s a ni pple wi th flange to be co nnec ted

.

wi th a flanged 5 i n tuyere p i p e; on the lower si de i s a 5 i n slag escape closed

-
.
- -
.
-

by cardboard k ep t i n place by a holder ; i n the cover at tached to the rear end ,

by hi nged bol ts are tw o Openi ng s the glass covered p eep hol e and th e 4 i n
, ,
- -

,
-
.

o u tlet for th e escape of th e gases when the b last i s shut Ofl Whi le the blast is .

on , t h e autom ati c valv e provi d ed wi th adj ustabl e co unter w ei gh t i s pr essed

,
-

by th e blast agai nst the seat of the 4 i n escape ; when the blast i s OE th e valve -
.
,

H o l der

FI G S . 2 03 and 2 04 .
— Eilers auto mati c cut ofl -
tuyere .

closes th e blast i nlet and -

b ack p ressure
Op ens the o utl et, thro ugh whi ch the -

i n the f urnac e forces the gases i nto the op en The tuy ere i s exc ellent when .

ev ery t hi ng i s w orki ng norm ally ; t ro ubles ari se w hen dirt or slag gets i n acci den
ta lly causi ng leaks Or warp i ng the di sk
,
.

The M essi ter tuyere has ano ther devi ce to pr event the back flowof fur
-
l -

nac e gases i nto t he tuyer e pi pe

- -
.

T he Anderso n t uyere used by the U S Sm el ti ng Refini ng and M i ni ng Co

,
. .
, ,
.
,

a t M i dval e U tah i s sho , wn i n Fi gs 2 05 2 1 2 The cast i ro n tuyere box clamp ed

,
— . .
- -

t o th e j ack ets has an 8 i n sock et to rec ei ve the b all of th e sh eet i ro n t uye

,
-
. re -

p i p e a s
,
la g o u tl et clo sed -
by a ni ppl e cap and l ead was h er and a t uyer e bo x , , ,
-

cap wi th lugs ti gh tened by m eans of cap scr ews .

The Traylor t uyere used at Trai l N or thp ort and Kellogg i s shown i n
, , , ,

Fi g 2 1 3
. T hi s com .bi nes several i nteresti ng fea tures The cast i ro n tuyere box .
- -

‘
U S Patent, NO 70633 2 , Aug 5,
. . . . 1 90 2 .

16
24 2 ME TALLURGY OF LE AD

is clamped to the j ackets by m eans of hook s fasteni ng i n open lugs ; the hooks

threaded at one end are ti gh tened by m ea ns of nuts and th e joi nt b etw een box ,

Valve Pi n
( G ro und to Al t ti gh t F l t
-
)

Secti on A A
Cast
-

2 34 Close mr
pp e
11 0“

T uyere Bo x Cap
M W m :

FI GS 2 05 to — Anderso n t u ere
. 21 2 .
y .

G ets Val ve

Fuetbl e or Fast eni ng In O pen Lu

Wood en Pl ug

FI G — Tra lor tu ere

. 213 .
y y .

and j ack et is mad e ai r-

ti gh t through an asbestos gasket held i n a groove of the
box . The box has the Robi nso n sa l g -
escap e
l
closed by a fusi ble or a wooden
1
E ng
. Mi n J
. .
, X XV
1 908, L X , 2 5 1 , 1. xxxvr, 756 .
244 M E TALLURGY OF LE AD

TAB LE — CO N N E RSVI LLE RO TAR Y BLO W E R

56 .

Machi ne length by
Di sp lacement ,

Power
pe
wi dth by hei ght ,
rev , cu ft . ai r
in
. .

Th ere wo ways of supplyi ng blast to a number of furnaces E ach

are t .

furnac e can have i ts own small si ze blower or several large si ze blowers d eli ver -

,
-

the com p ressed ai r i nt o a blas t mai n fro mwhi ch th e sever al f urnaces are sup
-

m m
.

p li ed T
. h e fi r st et ho d i s th e or e d e si r abl e as a f ur nace can b e r un i nd e ,

pendently fro mi ts nei ghbors whi le at the same ti me i t can be cross connec ted ,
-

wi th a mai n leadi ng to other furnaces and assi st i n ti me of need The seco nd i s .

the one generally acc ep ted as the plant i s cheaper the care easi er and th e r epai r
, , ,

sm all er ; i t i s however d esi rabl e th at the blowers be of the sam

, , e si ze The .

volume of ai r deli vered t o the several furnaces wi th the second met hod i s
regulated by a gate i n the branch pi pe -
.

The blast m ai n
s are of plate i ro n -
The m ai n bl ast pi pe or i nduc ti o n p i pe .
- -

whi ch recei ves the ai r fro mseveral blo wers has a di ameter one thi rd larger t han -

the co m bi ned o utlets of the blowers The mai n usually runs along the back s of .

a rowof f urnac es near the d ust cham ber and i s suspended 8 ft or more above the -

, .

furnace floor I t has safety or reli ef val ves and i s clo sed at bo th ends by gate
.
-

valves If one of the f urnaces i s to stop for a shor t ti me one of the gate valves
.
,
-

i s sli ghtly opened and so m e ai r allowed to go to waste; thi s i s a m ore conven

i ent proc ed ure than red uci ng the speed of the engi ne In each branch pi p e .
-

connecti ng a blo wer wi th th e mai n pi pe there i s a gate whi ch i s closed when the
blo w er i s not i n use as o th erwi se i t m ay happen th at the i dle blo w
, er wi ll be

r unni ng back ward .

Fro m the blast m ai n branch pi pes each provi d ed wi th a gate valve fur
- -

,
-

ni sh the blast to the b ustl e pi pes of the several fur naces Fi gs 1 76a nd 1 8 1 -
The , . .

b ustle pi p e whi ch enclo ses t wo si des and one end of a furnace Fi g 2 1 4 has on
-

, ,
.
,

the up per surface cast i ron gas vents the deta i ls of whi ch are shown i n Fi gs
- -

,
.

2 1 5 and 2 1 6 The openi ng of the v ent 1 0 i n i n di am

. et er has bol t ed to i t the ,
.
,

valve seat through the center of whi ch passes a gli di ng brass valve rod wi th
-

,
-

handle carryi ng at i ts lower end the valve a brass plate The rod fits snugly ,
.

i nto th e op eni ng of a r ubber w asher The co m bi ned wei ghts of valve and rod .

are so adj ust ed that the valve w hen p ulled wi th the handle wi ll remai n i n , ,

place when the blast pressure is norm al ; i t will si nk when th e pressure fal ls
-

.
 S MELTI NG LE AD OR E S I N TH E BLAS T F URN A CE

On the lo wer si d e of a b ustl e pi p e thi downward to be connected

bles pass -
m
m
wi th the tuyeres For erly the connecti on was made wi th closely woven
.

canvas bags Fi g 1 73 whi ch had been so aked i n water glass alum or mi neral
, .
,
-

, ,

pai n t t o pr event cat chi ng fire fro mspa rks A t hi mbl e had a sli de da mp er to .
-

permi t sh ut ti ng ofl the blast wholly or partly fro ma tuyere , ,

.

Wi th hi gh pressure blast the leakage becam e so gr eat th at the bag w

-
as re

placed by an i ron pi pe provi ded wi th a gate valve -

.

FIG 21 4 . FIG 21 5 . F10 21 6.

FI G . 2 14 — B ustle—
. i
p pe wi th gas vents -
. FI GS . 2 1 5 a nd 2 1 6 — GaS .
-
vents o f bustle p i p e -
.

The blast i s measured wi th q ui cksi lver water or glyceri ne

pressure of the , ,

gauges ; a di fi erence i n level of 2 i n q ui ck si lver or 2 8 i n water or i n glyc eri ne . . .

( p
s gr
. e
.q ual s 1 lb or 1 6 o z av d p pressure p er sq i n W ater and glyc . . . . . . .

eri ne are of t en colored or a drop of i nsol uble colori ng m atter i s added to each ,

li mb t hat the level may be plai nly seen Most works at present have i n the .

blower roo ma recordi ng gage whi ch sho ws the vari ati ons i n pressure of blast
i n 2 4 hr The recor der of th e B ri stol Co W aterb ury Conn , i s th e one m
. ost .
, ,
.

frequently found .

1 1 4 H andli ng Ores
. Fluxes and Fuels The r ecei vi ng and di spo si ng of the. .
-

rawm ateri al s for the bl ast f urnac e for m s p ar t of t he general arrangem ent of the

whole plant wi th i ts operati ons of sampli ng and stori ng of materi als Of ro asti ng ,

and blast roasti ng prep ari ng sm el ti ng charg es and di sposi ng of , p ro duct s as ,

well as the di sposi ti on of power wat er and o ther necessari es The correc t , , .

sol uti o n of thi s engi neeri ng prob lem m ay i nvolve the success or fai l ure of a

p l an t a nd
,
i s t oo l arg e t o be ta k en u p h er e i n de tai l .

Th ere have taken place m any di sc ussi o ns as to wh eth er a terraced or a level

si t e i s b est sui ted for a pl ant but the vi ew s expressed di ffer gr ea tly al tho ugh
1
, ,

Locke ,
“S
melti ng Pl ants,
”
Ci nci nnati , 1 883 .

Austi n, Tr A I , 8 6
9 , xx.vr, 3
88 . . M . E . 1 .

Vezi n, ibid , 1 09 5 ; E ng Mi n J 1 89 7, Lxrv,

. . . 1 2 3.

Edi tor, Mi n Reporter, 1 904 , L, 3 76 . .

La ng ,
E ng . Mi n J . 1 0
9 ,7 L XXX III , 565 .

Austi n, M .
, 7 2 6 .

Moore , lac . ci t , 1 908, L

. XXXV , 54 6 .
24 6 ME TALLURGY OF LE AD

e ev rybody agrees upon the necessi ty of havi ng am ple fall and space for the slag
dum p The handli ng of m
. ateri al s by bel t co nveyors has weak ened th e case

of the advocates of a terraced si te .

In the prec edi ng edi ti on Of thi s book draw i ngs and descri pti ons of severa l
well arranged plants were gi ven Some of these plants have been abandoned ;
-
.

o thers have been al tered to meet the present requi rements of mechani cal hand
li ng of m ateri als i n the preparati on of charges and the di sposal of prod ucts .

The m oderni zed works cannot serve as models The only newplant i s tha t .

of the Bunker H i ll and Sulli van Mi ni ng and Concent rati ng Co at Kellogg .

,

Idaho ; ano ther has been proposed for Chi na but not erec ted ; both are t reated
l
,

in §1 2 2 .

FI G . 217 — O re -
bed .

So me plant s si t uate d i n the N or th

have to handle i n wi nter frozen concen
t rat es . These have been thawed out e g on a strai gh t l i ne heated h eart h ,
. .
,
-

over whi ch travel scrapers Thi s method i s expensi ve and i s li kely t o mak e
.

much dust especi ally wi th flo tati on concentrates Crushi ng the frozen ore
, .

wi th too thed rolls and then red uci ng to desi red si ze wi th a swi ng hammer -

p u lv eri ze r i s m or e sa ti sf ac t ory es p ec i ally as flo ta

, t i o n co nc en t r at es for mgr anules

whi ch gi ve up thei r water only when they have been fed on to the Dwi gh t Lloy d -

S i nteri ng m achi ne and are not handled b efore th ey have b een si ntered wi t h

the charge to w hi ch they had b een added .

In order to m ak e po ssi b le a gener al di sc ussi on of the handli ng of rawm a

teri als i t i s exp edi ent to consi der wi th so m

, e detai ls the m etho ds followed by ,

the o lder and the r em odeled plants i n recei vi ng the raw materi als and p re
p a ri ng t h e ch arg e s w i t h m a nua l la b or and m e ch a ni c al d evi c e s .

E ng . Mi n J. .
,
1 9 1 6, CI , 868 ; Mi n Sc . . Press, 1 91 7, c m , 1 55 .
24 8 M E TALLURGY OF LE AD

Plant A — In Fi gs 21how8n tand

he p lan an
21d cr oss sec ti n
are s
o of
9
-
. .

beddi ng bi ns and ore p ockets of a la rge smeltery ; the sec ti on i s drawn to a

- -

larger sc ale than the plan i n order to b ri ng out detai ls The plant i s 335 ft . .

wi de and 51 2 ft long and covers an area of

.
, sq ft For the recepti on . .

of the materi als there are provi ded the N orth and South ore beds and the -

N or th and So uth ore hoppers or pockets on the Si des Of the central coke
- -

b i ns ; usually the cok e i s unloaded fro mthe cars di rectly i nto the buggies .

The m at er i al s arri ve i n c ars on elevated track s and are di scharged ei ther by ,

hand fro mthe si de of a car or drop ped fro mthe bo tto m .

F1 G 21 8 .

S ECT IO N A B -

FIG 21 9.

FI GS 8 and — Plant A; p lan and cross secti on of beddi ng bi ns and ore ockets
21 219 p
- - -
.
. .

For the b ed di ng of ores there are p rovi ded t wo sets of four bi ns 1 6 by 2 0 ft ,

.

and 1 6 ft 6% i n hi gh each holdi ng abo ut 50 t o ns of ore

. .
, A set recei ves i ts .

ore thro ugh tw o el evated track s The ore i s sam . pled by frac ti onal selecti on;
the di scar d i s transferr ed by wheelbarro w s fro mthe cars to the b i ns and spread .

Ore and fl ux to be stored i n the hopp er shaped bi ns arri ve as a rule i n bottom -

di scharge cars on elevated tracks There i s p rovi ded a large bi n for storage
.

of coke whi ch i s to sup ply the f urnaces i n case the dai ly Shi p ments c ease tempo
rari ly; usually the coke c ar s are em p
-
t i ed i nt o w h eelb arro w s O r e fl ux a n d .
,

coke are wheeled to the charge shed and emp ti ed there i nto a charge car on a
- -

dep ressed track i n the chargi ng p i t care bei ng t ak en to dump the charge com
,
-

o n n t i n r e cr i b ed o rder i n such a m a n ne r th a t th y for m l ay r cok i i n

p e s p s e e s ; e s

troduced last i n order to di m i ni sh breaki ng by the i m pac t of the charge whi ch ,

SM EL TI NG LEAD ORE S I N TH E BLAS T F URNACE 24 9

su n
g 10 n e w
250 M E TALLURGY OF LEAD

wei ghs lb An i nclined scharge car to a trans

. hoi st deli vers the bo tto mdi
-

fer car on the feed floor whi ch i s m

-
oved to and fro by elec tri c trac ti on spo tted
-

, ,

over the throat of a furnace wher eupo n the contents of the charge car are ,
-

dropped .

Detai ls of thi s arrangem ent are gi ven i n plan and verti cal sec ti on i n Fi gs .

2 2 0 and 2 2 1 The plan show s i n the i ron plate pl atform the Openi ngs 1 0
.
-

ft by 2 ft 4 % i n of the t w
. o chargi ng pi ts i n the chargi ng sh ed of Fi g 2 1 8
. .
,
- -
. .

The openi ngs have on the si des L shaped angles 4 by 5 by i n agai nst whi ch -

, .
,

t he hand p ushed cars b um p when they are bei ng di scharged Thei r contents
-
.

are recei v ed i n tw o charge cars 1 1 ft 9 i n by 3 ft and 3 ft 6 i n deep traveli ng -

,
. . . . .
,

—
on a t rack of 3 ft gauge ; a car holds 5 6 t ons charge The cars 7 ft below the
-
. . .
,

floor are rai sed 30 ft by a di rect hoi sti ng cable to the feed floor on tw
, o incline
s .
- -

FIG 223 .

Fro 224 .

S ECT IO N A A
F1o 222 .
Fxo 225 .

FI G . 222 -
2 25 — Unloadi ng
. and beddi ng di rect ore .

of 28 g r ad e
°
whi c h co m b i ne to a s i ngl
, e li ne l eadi ng at the cr e st of the i ncl ine
to the transfer car on the feed floor whi ch has a gauge of 1 4 ft 8 i n
-

Wh en the -
. .

charge car has been unh ooked i t i s t ransferred to a furnace emp ti ed and re
-

, , ,

t urned to the hoi st ; the hoi sti ng cable i s hook ed on and th e car lowered i nto -

the chargi ng p i t A swi tch at the upper end of the i ncli ne deflects the car to
-
.

i ts proper track .

Thi s m ethod of rai si ng the charges to the f eed floor i s si m i lar to the one i n -

operati on at East H elena Mont l

,
.

Plant B — A com bi nati on of beddi ng ores mechani cally and transferri ng the
.

mi xture by hand to the feed floor of th e blast f urnaces i s represented by plan -

si d e and end el evati o ns and sec ti o n i n Fi gs 2 2 2 2 2 5

- — The di rec t or es t hat , . .
,

i s oreS to be b edded and sm

, el ted raw arri ve i n box cars on tw o track s ; th ey are ,

unloaded by hand fro mthe p latform s 3 ft 3 i n h i gh o nto a chai n co nv eyo r ,

. .
,
-

2 ft 7 i n hi gh runni ng betw
. . een the p l atform s ,
The co nveyo r whi ch has pans .
,

D wi ght ,
Tr A I . . . M . E .
,
1 90 2 ,
m m38 ,
2.
252 M E TALLURC Y OF LE AD

Both r g m ents provi de for the beddi ng of ores but i nvolve consi d erable
a ran e ,

manual labor plant A more so than plant B The present tendency Of lead
, .

plants i s to gi ve up the beddi ng system to handl e ores mechani call y and to -

, ,

make up charge mi xtures i n a Si mi lar manner -

.

Plant C shown by a sec ti on i n Fi g 2 2 6 represents the storage and beddi ng

,
.
,

bi ns of the lead plant of the Internati onal Smel ti ng Co Tooele Utah

-
1
.
, ,
.

The seri es Of 2 6 V shaped bi ns i s 2 60 ft long and 3 2 ft wi de -

At fi rs t a V . . .

shaped bi n w as di vi d ed by a c ent ral w all i nto tw o com par tments ; there were i n
Oper ati o n 52 bi ns whi ch were 1 6 ft long As the ores dropp i ng fro mopposi te . .

bins i nto the cars below were not sati sfac tori ly m i xed the c ent ral wall has been ,

removed and only the steel frami ng retai ned Th ere are i n use therefore 2 6 bi ns .

whi ch at the base of the V are 3 2 ft long 1 0 ft wi de and have a maxi mumdepth .
,
.
,

Of 2 4 ft ; a bi n 01 p ock et has a capaci t y Of

. cu ft and holds about 500 t ons . .

lead ore The several pockets recei ve the ores ei ther di rec t fromrai lroad cars
.
,

or through a 2 0 i n bel t conveyor 82 0 ft long and a Robi ns automati c t raveli ng

-
.
, .
,

t ri pper Thus fine ores and conc entrates are usually unloaded di rec t from
.

ca rs whereas other materi als go first to the cr ushi ng plant whence they arri ve
,

by the belt conveyor A pocket i s closed by a ci rc ular hand Operat ed gate .

-
.

The ore i s di scharged i nto a suspended w ei ghi ng hopper provi ded wi th Fai r -

banks susp ended scales havi ng i ndependent beam s The wei ghed m ateri als of .

t he hop pers are em p ti ed i nto the charge cars runni ng slowly to and fro on the -

bottomt rack SO that they are uni formly spread i n the cars Ore that i s to go to
, .

the Dw i ght Lloyd si nteri ng m achi nes i s di scharged i nto cars 1 2 ft long and 4 ft
-
. .

wi de holdi ng from3 to 5 tons ; materi al whi ch goes to the blast furnaces i s col
lected i n hopper bo t to mcharge c ar s havi ng tw
— o drops whi ch are 1 4 ft long and 5 -
.

ft wi de and hold fro m5 to 8 to ns

.
,
A charge car has fo ur wheel trucks at each .
- -

end and i s m
,
oved by a rai lway typ e motor geared di rec t to the axle A car -
.

th us has t w o m o tors whi ch are operated at one end through a street rail way -

type controller The drop doors and brak e m echani smcan be operat ed from
.
-

ei t h er end of the car The charges for the five charge ca rs of the five blast fur
.
-

nac es are m ade up p er shi f t by 1 forem an 3 loadi ng m en 2 m otor men and 1 , , ,

laborer who shovels i n drosses On the f ur nace floor are 1 forem an 2 feed ers .
-

, ,

2 helpers 1 laborer and 1 cok e wei gh er

,
Thus 1 4 m en handle p er shi f t f rom
,
-
.

to tons ch arge .

Plant D — A cross sec ti o n showi ng one of the co ncrete b i ns the til ti ng

.
-

wei ghi ng hoppers and recei vi ng charge cars of the Co nsoli dated Mi ni ng and
- -

Sm el ti ng CO at Trai l B C i s show n i n Fi gs 2 2 7 and 2 2 8

. The Si x el evated
,
. .
,
. .

co ncrete bi ns of a sec ti o n r ecei ve thei r m ateri al s fro ma track not sho w n ; they
have co nvex fronts and backs and parall el si des and each has t hree di sch arges ,

ft wi d e . A bi n 1 8 ft lo ng 1 6 ft 6 i n wi de and 1 4 ft deep has wi thout

.
,
.
,
. .
,
.
, ,

the di scharg e a capac i ty of cu ft and hold s abo ut 4 50 to ns l ead ore

,
. . .

The di scharge op eni ngs 1 6 by 2 4 i n are par tly clo sed by gates
-
The ore i s fed
,
.
,
.

froma bi n by li nk belt conveyors havi ng metal curtai ns A conveyor when -

.
,

I
Th o m Si cke, Tr A I
son -
. . . M E .
, 1 9 1 3, v x, 94 6 . Pri vate note
s, and co mmuni c ation

by W . W rai th , J uly, 1 9 1 6 .
S MELTING LE AD OR E S IN TH E BLAS T F UR N ACE 253

—s o J
' '

l 11 B ar

[5 1 15

k _

2 28 — Charge bi n
.
-
and wei ghi ng hOp p er
-

,
Trai l B . C
.

FIG 229
.

FI GS . 2 2 9 and 2 30 — Charge bi n and scale lorri e,

.
- -
Mi dvale, Utah .
254 ME TALLURGY OF LE AD

in mo ti on p d of 50 ft p er mi n deli vers the ore i nto a ti lti ng

at a s ee . .
,

recei ver p rovi ded wi th a b eam scale The recei ver emp ti es autom a ti call y .

i nto the charg e car beneath when i t has rec ei ved i ts predeterm
-
i ned am ount
of ore .

Plant E —A very recent i nstallati o n i s that of the Uni ted States Sm

. el ti ng ,

Refini ng and Mi ni ng Co at Mi dval e U tah whi ch has reduced the num

,
l
. ber of , ,

men requi red o a v ry low figure

t e Fi g 2 2 9 g i v es a cro ss— se c ti o n t hro u gh th e . .

ore b i ns and Fi g 2 30 a si de vi ew of the Robi ns tr i pper

-

,
. The m ateri al s are
-
.

collec ted i n three rows of bi ns each wi th i ts track beneath On the track s , .

,

co nnec ted by spri ng swi tches travel the scale (charge collec ti ng) cars One-

,
-
.

row of bi ns has flat bo ttoms ; they rec ei ve sam pled oxi de ores to be bedded and ,

are provi ded w th pai rs of rec procati ng underc ut arc gates

i i — The bedded ore .

i s cut do w n by tw o m en i n a bi n and shov el ed to the arc gate The o xi de ores -

.

are di str i b uted on the b ed s by m eans of a slo wm ovi ng Robi ns tri pper whi c h -

di scharges fro ma belt conveyor To the standar d i s at tached a carri age whi ch .
,

runni ng on a track below the level of the bel t conveyor has an adj usta ble ,

spo ut to perm i t del i veri ng the ore to the near or far si de of the bi n Th e .

tri pper prop er has m o unted on i t a seat for the Operator who starts and stop s
the tri p p er and adj ust s the m , ovable sp o ut The o ther two rows havehOp p er bot .
-

tombi ns for roasted ore i ron ore li m esto ne cok e etc A bi n i s di scharged by a
, , , , .

pai r of (Leviathan) bel ts The di scharges of the bi ns are wi de the combi ned .
,

wi dth bei ng a li ttle less than the leng th of the charge car; they th erefore fill the -

car uni form ly thro ugho ut i ts leng th The di scharge gates are Op erated by a .
-

75 p
. h-
m
. o t or o.n th e ca r T h e car ha s a bo ut th e s a m e l en g t h as t.ha t of t h e

throat of the blast fur nace; i ts capaci ty i s 1 2 0 cu ft It i s m ounted on two 4 . .

wheel swi vel trucks and one p ai r of small g ui de wheels whi ch per mi ts runni ng
- -

o n sharp c urv es The car carri es a 1 9 .

5 00 vol t d i r ec t c u rr en t t r av el m o t or - -

whi ch dri ves i t wi th f ull load at a speed of from600 to 700 ft p er mi n . .

There are provi ded i n addi ti on a 7 5 h p m o tor for Openi ng and closi ng the .
-
. .

gates and a foo t brak e The hopper frame of the car i s suspended on scales
,
-
.
-

havi ng mul ti p le beams The scale poi nter i s p rovi ded wi th a plus and mi nus .
-

b eamwhi ch i s set before every wei ghi ng i n such a manner th at the poi nter
moves when the wei ght i s 1 00 lb shor t of the final wei ght By setti ng the . .

auxi l i ary beamon t he zero m ark the w ei gh er can add th e m i ssi ng am ount and ,

ob tai n an accurate wei ght I n Op erati ng th e car i s stopped beneath a gate and .
, ,

the gate m echani sm co nnected wi th the 7 5 h p m

-
o tor by thro wi ng a lever ; .
-
. .

thi s breaks the c urrent connec ti o n w i th the trav el m o tor and makes i t i mp ossi bl e
for the car to move whi le i t i s connec ted wi th the bi n gear When the gate .

has deli vered i ts prop er am o unt of ore i t i s clo sed the co nnec ti o n i s broken , , ,

and the trav el m o tor star ted In thi s manner as many as ei ght co mponents .

of a charge can be dropped At Mi dvale the scale car i s run on to a bri dge .
-

over a charge—car and i ts co ntent dropped ; 2 4 men handl e i n 2 4 hr .

Edi tor, E ng M i n J , 1 9 1 5, c, 5 1 9
. . . .

Anderson, op ci t , 1 9 1 6, CI , 885 . . .

Pri vate notes, 1 91 6 .

256 ME TALLURGY OF L EA D

Tabl e 53) i s shown i n Fi g 2 3 1 , whi ch needs no fur ther co . mment . The wheel
is m
oved by hand as soon as the old i n front of the Spo ut well i s filled m of the .

The bars of lead are rem oved by hand and transferred to the drossi ng kettle -
.

A drossi ng kettle of 2 0 to ns capaci ty i s 6 ft 4 i n i n di am

-
eter and 3 ft deep ; . . .

a 30 ton k ettle 8 ft 1 0 i n i n di am
-
eter and 3 ft 4 i n deep ; drawi ngs of kettle
. . s are . .

gi ven i n § 2 4 7 .

Before chargi ng th e k et tl e and whi le i t i s bei ng heated to recei ve li q ui d lead the ,

bo tto mi s someti mes covered wi th ashes The ashes m ak e the dross dri er that .
,

eat i ng

u
4 x 4 a h la

15 C Mant l e
n of
ear Furnace

, aS h aft

S p out

Tonof C reel anr

o mn a

FI G . 2 31 .
— Casti n
g
-
wheel for lead bulli on, North port , Wash .

i s, th eycause i t to retai n less entangled lead When a kettle i s filled wi th liqui d .

lead the tem

,
perat ure i s allowed to fal l to 4 80 C before i t i s drossed l
When °
. .

the dross has been rem oved the lead i s poled wi th ai r unti l the decreasi ng tem
,

p erat ure r each es 3 60 C th e ri si ng dro ss i s r°

emov ed fro mti me to ti m e Th e .

tem perature i s now rai sed to 380 C when gumdrop samples (ladle °
.
,
-

sam ples wei ghi ng about 0 5 assay ton) are taken; i t i s rai sed furt her unti l i t
.
-

reaches 4 2 5 C , wher e p on the lead i s cast

°
.
°

The dross i s usually ski m med i nto a H oward press to rem ove as
much as p ossi ble adh eri ng lead Thepressed dro ss usually goes di rec t to the blast .

f urnac e charge; someti mes i t i s fur ther freed fromlead by li quati ng i n a rever
Weeks,
Tr A I
. . . M . E .
,
1 91 5, LII , 71 1 .
 S M ELTI N G L E AD OR E S I N TH E BLAS T F URN ACE

beratory furnace . dry dross i s allowed to accumulate and

At so me work s the
a dded to t he bl ast f urnace when sufli ci ent has been coll ec ted to have a de

ci ded i nfl uence upo n the Cu co ntent of the resul ti ng m atte -

.

Moldi ng of lead i s tak en up i n § 2 53 .

1 1 6 Poli ng Lead
.
— Thi s ter m si gni fi es the m . echani cal sti rri ng of li q ui d

l ea d by means of co mp ressed ai r at a tem —

perature of 400 500 C i n an open °
.

k et tle The obj ect of the operati on i s to bri ng to the surface i mpuri ti es held
.

i n suspensi on by the lead When they ri se to the surface they becom . e Sli gh tly

o xi di zed and rem ai n on the surfac e of the heavi er lead b ath w hence they are ,

removed as a more or less pasty m ass call ed dross by ski m mi ng wi th a p er , ,

fo rated di sk 1 0 1 2 i n i n di am
—
, eter ri veted to a pi pe handl e 6 ft or m
. ore i n ,
-

, .

l ength havi ng a T handle

,
-
.

The p uri ficati o n of lead by drossi ng i s consi dered i n § 2 4 1 .

Poli ng of lead b ulli on w hi ch i s usually shi pped to a di stant refinery i s or

, ,

r ec ent date I t has beco me co mmon prac ti ce wi th smel teri es as by removi ng

.
, ,

t h e dross fromthe b ulli on the dross rem ai ns at the sm el t ery w here i t belongs
, ,

a nd the lead freed fro mdross can be sati sfac tori ly sam p l ed for d e t er mi ni ng th e

c o ntent of preci o us metal .

Im puri ti es such as As and Sb whi ch are alloyed wi th the lead and removed
, ,

o nly to a very sm all ex tent by poli ng are tak en ca r e of i n the refinery by the ,

o p erati on of sof teni ng

Wi th lead that i s hi gh grade and suffi ci ently free frompreci ous metal to go
s t rai gh t t o m ark et poli ng at the sm el t ery i s ab solutely necessary as all pri m
, ary ,

lead retai ns so m e i nterm i ngled i m puri ti es whi ch have to be removed b efore i t

ca n be used i n t he m et al i ndust ri es .

For m erly a gr een p ol e w as thrust i nto the l ead The gases and vapors set .

fr ee sti r up the lead and expose conti nuall y newsurfaces to the oxi di zi ng ac ti on
of the ai r Th us most of the Cu and S and small amounts of As Sb Zn and
.
, , ,

F e are slo w ly oxi di zed and collect on the surface as a dross I t tak es abo ut
,
.

2 hr to pol e a k et tl e
. .

Later a crutch w as used to keep a sti ck of green wood hori zontally d epr essed

i n the lead A crut ch consi sts of a pi ece of flat i ron long eno ugh to reach abo ut
.
-

1 % ft over the k et tl e upon whi ch i t i s placed and wei gh ted w

. i th a co uple of
bars of lead at ei th er end To the fla t i ron are ri v eted t w o ar m
. s say 2 ft 6 i n -

,
. .

lo ng and 2 ft apar t forked at the ends whi ch reachi ng i nto th e lead r ecei ve the
.
, , ,

wood ; they are connec ted halfway down by a cross pi ece of flat i ron Usually - -
.

t h e crutch w i th i ts bi llet of green w ood i s p ut i n place before the kettle i s filled ,

as thi s obvi ates th e tedi ous work of depressi ng a green sti ck i n hot lead .

In m odern p lants whi ch have avai lable steamand comp ressed ai r poli ng
, ,

wi th wood has been replaced by i ntrod uci ng steamor pr eferably ai r near the bot
t omof a kettle through a I or 1 5 i n pi pe bent to t he for mof the k ettle and .
-
.
,

p assi ng downward through the lead The pi pe bent over the ri mof the k ettle .

is w ei ghted wi th b ars of lead or the ri mhas a clam p whi ch holds i t i n p lace

,
.

In usi ng steam i t i s i m portant that an auto mati c trap be placed near the
,

k ettle to remove condensed w ater .

17
258 ME TALLURGY OF LE AD

At H erculaneu m Mo , .
,
1
the lead is steampoled
-
by means of the Bardi ll
apparat us gi ven i n Fi gs 2 32 and 2 33 I t shows two connec ti ng concentri c pi pes
. . .

The i nner pi pe open at the ends i s screwed at the top i nt o a cap whi ch closes
, ,

the outer pi p e and has an op eni ng i n i n di ameter leadi ng i nto a cyli nd ri cal .

recei ver fill ed wi th Spo nges and connected wi th pr essure water The outer p ipe
— .

forms a generati ng cham ber fro mwhi ch steami s wi thdrawn at the si de through

S h i eld

FI GS . 232 and 2 33 — Bardi ll poli ng ap p arat us

. .

an e lbow and passed downward through a deli very pi pe The apparatus i s -

.

lowered i nto the lead bei ng suspended by a chai n block froman overhead trol
,
-

ley and h eated by the lead

,
Pressur e water freed fro mpossi ble susp ended
.
-

matter by the sponges enters the i nner p i pe through the capi llary openi ng i s
w
, ,

vapori zed i n i ts passage down ard i n the i nner and up ward i n the outer pi pe ,

passes near the top of the latter i nto the deli very pi pe and p oles the lead The -

, .

appar atus i s cheap effec ti ve and easy to handle but care has to be had to avoi d
, , ,

explosi o ns .

1 1 7 H andli ng M atte and Slag General

.
’—
An i m agi nary cross sec ti on , .
-

thro ugh th e cr uci bl e of an operati ng f urnac e would S how the cr uci ble filled wi th

Bardi ll , E ng Mi n J , 1 9 1 5, c, 9 69
. . . .

Braden, Tr A I M E , 1 886, xxvr, 38

. . . . . .
260 M E TALLURO Y OF LE AD

catch p ot Fi gs 2 34 and 2 35 Ordi nari ly the slag i s allowed to harden fromthe

-

,
. .

surface down to a dep th of a fewi nches the i nlet and overflo wbei ng kep t open , .

The hardened slag p r events the li q ui d slag below from coo li ng and thus pro ,

mo tes a good separati on Of mat te and slag .

F1G 234 .

FIG 23S .

FI G S . 2 34 and 235 .
— Slag p ot , hand draw
- -
n .

In order to
do away of m
wi th the necessi ty ovi ng the heavy overflowpot
-

wh en filled wi th m at te a tap hole has b een placed near the bo tto mas show
,
l -
n

i n Fig 2 37 . Matte i s p eri o di cally di sch arg ed thro ugh i t i nto an or dinary slag
.

p o t A
. s th i s tap i s li k ely t o w ear a w ay q ui ckly T erh u n e F i 2
g 3 8 ma de i t , ,
.
,

detach able .

l
B raden, Tr A I . M E
. .
,
1 896, XVI , 38 .
S M ELTI NG LE AD ORE S I N TH E BLAS T F URN ACE 26 1

FIG . 2 36
.
— O verflowslag p ot , handd n
-
wn .

Fro . 2 37 —.Overflowslag pot -

wi th matte tap-

,
hand draw
-
n .

FI G . 2 38 .
—Overflowslag pot wi th
-
Terhune detachable matte tap
-
.
262 M E TALLURC Y OF LE AD

I nstead of usi ng an overflowp ot to collec t m atte there w as i n Op erati o n for -

so m e ti me a ca tch p o t wi th tap hole above the level to whi ch the m

-
atte w as ex -

e cted to r each ; the sti ll li q ui d slag was tapp ed i nto a waste slag p o t and t he
p
- -

matte i n the bo ttomremai ned undi sturbed and was allowed to soli dify The .

sl ag sh ells w
-
ere r etur ned to th e blast f urnace Such po ts went by the nam e of .

D eveureux p o ts Deveureux havi ng tak en out several patents ; drawi ngs are
,
l

FI G 239 .

FIG . 2 3 00

FI G S . 2 3 9 and 2 3 ga — . Posi t i o n o f f
o e hearth
r — bet ween blast furnace a nd waste slag pot .

gi ven i n the p recedi ng edi ti o n The p ri nci p le i nvolved i s however of an earli er

.
, ,

ori gi n than i s generally suppo sed Kerl states th at such a p o t was already in
’
.

use ni 1 8 73 at Sch em ni tz H ung ary ; Pai nter r epor ts i ts use at S tolb erg Prussi a
3
, ,

at the sam
,

e date and Vi vi an as early as 1 8 6 tapped the li q ui d sl ag from

‘
c n es
, 4 o

pl aced on the dum p and saved the sc ulls whi ch alone were resmel ted , .

U S Patents, N o 3 1 2 4 39 , Feb 1 7, 1 885 ; N o 33 5 1 1 4 , Feb 2 , 1 886

. . . . . . .

3 “ r
G undri ss der Metallh ii ttenkunde, Feli x, Lei p si c, 1 88 1 , p 1 00
”
. .

3 “ e
R p ort on t he M etallurgy of Lead, Si l ver, COpp er, and Zi nc at the Vi enna Interna
ti onal E xhi bi ti on of 1 8 73 , W ashi ngton, 1 8 75, p 6 1 . .

Eng . and Mi n . J .
,
1 88 1 , 3000 , 2 49 .
264 ME TALLURGY OF LE AD

b ui l t of cast i ron plates bolted together i s i ntended for a sm

-
all furnace; i t i s 4 ,

by 5 ft and 2 ft deep i nside the casti ngs and i s li ned wi th ordi nary red br i ck
. .
, .

I t recei ves the slag m atte fro mt he b last f ur nac e at one end and coll ec ts t he
-

matte whi le the slag overflows at the o ther i nto a ti l ti ng waste slag p o t wi th
,
-

bo wl 5 ft 6% i n i n di ameter ; the mat te i s tap ped at i ntervals i nto a recei ver

. . .

I t wi ll be no ted that the track s for the fore hearth and the waste slag p o t are - -

p l ac e d a t ri gh t angl es ; bo th are 36 i n g aug e -

. .

Wi th the prac ti ce rec ently i naugurated of allowi ng slag shell s to go to the -

d um p i nstead of resmel ti ng themi n the blast furnace to collec t thei r values ,

more attenti on has been gi ven to perfec t settli ng than used to be customary ;

FI G S . 24 2 to 2 51 .
— Fore heart h Colorado I ron
-

,
W orks , D enver , Colo .

hence the tendency at pr h v w fore hea r ths i n seri es

esent i s to a e t o bri ck li ned
- -

i nstead of one Such an arr angem

. ent i s Sho w n i n Fi gs 2 4 0 and 2 4 1 The slag . .

mat te i s tapped into the first bri ck li ned fore hear th whi ch is 935 by 4 % ft and - -
.

2 % ft d eep o utsi d e ; i t has an arch ed roof a lead tap on th e br i ck floor and a

.
,
-

matte tap 7% i n hi gher up The entrai ned lead i s tapped i nto a cast i ron slag
-
. .
-

p ot a
, nd t h e m at t e i nto a c ast i ro n bri ck li ned rec ei v er wh i ch ov erflow
-

s i nt o a -

Kilk er m at te car -
T he sl ag m at te whi ch h as dropp ed m ost of the mat t e
-

i n the first for e hear th or sett ler flows over a bri dge of fire br i ck i nto the second
-

,
-

li ned settler whi ch i s 1 0 ft lo ng 4 % ft wi de at the top and 3% ft at the bot tom

.
,
. .
,

and 3% ft d eep o ut si de . Thi s al so has an arched roof a m . at te tap at one end ,

-

and a slag overflowspo ut at the o ther whi ch d eli vers i nto a w aste slag o t 4 94
p
- -

ft i n di am
,

. eter Above the m atte tap i s placed an oil b ur ner to correc t an

.
-

y
-
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN ACE

c ooli ng of the slag I n the drawi ng the two settlers are placed at ri ght angles .

to one ano th er ; ordi nar i ly one foll ow s th e o th er i n a st rai gh t li ne .

A detai led draw i ng of a fore hearth co nstruc ted by the Colorado Iron Work s -

D enver Colo i s Shown i n Fi gs 2 4 2 2 51

,
— .
, The hear th 5 ft i n long 3 ft . .
, . .
, .

4% i n w. i de 2 f t 4% i n d ee
, p o utsi d e h as a 1 % ln bo tto mcasti ng I i n si de
. .
,
-
.
-

,
-
.

a nd end casti ngs streng thened by 1 i n r i b s ; the bo t to mhas up t ur ned r i n

- -
.
- -
.

bord ers to recei ve th e si de and end plat es ; at the cor ners bo ttom si de and -

end p la tes are fastened t og eth er by m

-
eans of i n bol ts The hear th has tw o -
. .

pai rs of wheels wi th 2 ft 6 i n centers runni ng on a 3 ft 9% i n gauge t rack ; -

.
-
.
-
.
-
.

t he slag overflowi s at one end and the m

-
atte tap i n t he m i ddle of one si de ,
-
.

T h e bri ck li ni ng i s sho w n to be 9 i n thi ck Such a heavy li ni ng i s approp ri ate . .

wh en maki ng matte and slag whi ch do not i ncr ust the hear th Wi th the .

z i ncky ores sm el ted at present und er co nd i ti o ns whi ch req ui re for eco no m ic ,

r ea so ns slags r unni ng hi gh i n Si 02 and CaO the li fe of a fore hearth i s too shor t

, ,
-

to warr ant p utti ng i n a 9 i n li ni ng I n so m e i nstances a for e hear th i s ex -

. .
-

ch a nged every 2 4 hr i n other s o nce every 2 or 3 days ; the latter i s the more .
,

co mmo n figure Wi t h two fore hearths i n seri es the first wi ll be freed fromlead
.
-

a nd m at te thro ugh tw o tap hol es ; the seco nd does no t co ntai n any lead T he -
.

bo t to mli ni ng of the fir st hear th b eco m

-
es very to ugh on acco unt of the lead that

i s present ; i t m ay req ui r e dri lli ng and bl as ti ng The bo tto mof the seco nd .

fo re heart h i s easi ly broken by d um

-
pi ng ; the larger pi eces are then passed
t h ro ugh a crusher .

Before li ni ng a fore hear th a ladle of waste slag i s po ured i n to close the -

j o i nts between the bo tto m and the end and si de p lates ; on top of the slag i s -

lai d a flat co urse of red bri ck ( bats) i n or di nary mor tar ; the si des also recei ve
o nl y a fla t co urse The sp ace surro undi ng th e m at te tap i s bri ck ed up
. It -
.

o ugh t to be sta ted that i n ore smel ti ng i t i s not absol utely necessa ry to li ne t he -

si d es at all but i t i s safer ,

In m att e sm el ti ng a li ni ng i s i ndi sp ensabl e .
-
.

A re li ned fore hearth i s dri ed and war m

-
ed by b ur ni ng i n i t cord w
-
ood for
a bo ut 2 4 hr When i t has been p ut i n place and matte i s run i n cord wood
.
, ,

i s k ep t b urni ng on the ri si ng slag and t he hear th i s kep t loosely covered wi th ,

p i ec e s of s h eet i ro n ; o n th e di sch arg e spo u t wo o d i s k e p t b ur n i ng t o co un ter ac t -

t h e cooli ng efi ect of the ai r .

A fore hea r th i s tapped clean before i t i s exchanged

-
.

A fore hea r th wi th co nti nuo us fl ag and m

-
atte di scharges w as i n operati o n -

a t N elso n B C but has not fo und use elsewh ere

1
. .
, .
,

I n a ReverberatoryFa rnace t he separati o n of m at te and sl ag w as fi rst carri ed

o ut by Rho des i n Leadv i lle and l ater by I les i n D enver Colo

“ It w as , ,
.

i n use at E l Paso Texas and i s i n Operati on at Map i m

‘
i M exi co and perhaps
,
5
, ,

o t h er plac es .

H arri s, E ng M i n J , 1 906, Lxxx r, 1 78 ; Can . . . . M i n Rev. .

,
1 906, xxvr, 141 .

H edley, J Can M i n I nst , 1 906, D1 , 58

. . . . .

Kloz, E ng Mi n J , 1 89 7, 358 . . .

m 69 5
.

Iles , p o . ci t .
,
1 899 , v ,
.

Vail, op . ci t .
, 1 9 1 4, XCVIII , 4 65 .

Easter, Tr A I . . . M . E . , 1 91 5, LI I , 71 6
Ri ce, E ng . Mi n . J .
,
1 908, l . xxxvr, 3 73 .
266 ME TALLURCY OF L EAD

HORIZO NTAL S ECT IO N

Fl o. 253 S ECT IO N T H RO UGH CENT ER

i
' '
s n
a si

F10 254 S ECTION

.

FIG S . 2 52 to 2 54 .
— Reverberatory matt e sep a rator
-
.
268 ME TALLU RG Y OF LEAD

p er ton . The v r g d Pb matte produced

Cu Fe p e r c e n t a e a e
l
, , , .

and Ag oz p er ton Wi th changes i n the charac ter of the blast furnace

. .

charges th ere occ urred tro ubl es owi ng to sp ei ss and z i nc m ush bo th r eq ui ri ng -

an i ncr ease of f uel i n or der t o k eep the set tler i n worki ng co ndi ti o n; but ev en

wi th hi gher temperatures i t became fil led wi th mush as q ui ckly as wo ul d an

ordi nary fore hear th Feedi ng scrap i ron to deco mpose ZnS when the li ber
-
11
.
,

ated Zn wi ll b urn O fl h elps m at ters but does not cure th em Th e o nly w

‘
,
ay , .

to get ri d of the m ush w as to allow the m atte to acc um ulate unti l i t had rai sed the
mush sufli ci ently to permi t raki ng i t out thro ugh a p ort cut for th i s purpo se .

It w as fo und that l eady copp er m at te ran hi gher i n Pb af ter l eavi ng th e sett ler

than wh en i t cam e fromthe bl ast f urnace i t h avi ng tak en up Pb fromt he ba th ,

on whi ch i t w as floati ng The diffi cul t i es wi th the set tler becam e so gr ea t th at

.

the foll owi ng m etho d of work i ng w as adOp ted : A blast fur nace i s provi ded wi t h

a rem ovable cast iro n box 2 ft 6 i n by 9 ft 2 i n and 2 ft deep li ned wi th 4 5 i n

-

, . . . . .
,
.
-
.

magnesi te bri ck whi ch serves to collect lead when th e well i s choked ; the fur
,

nace i s co nnec ted wi th the box by a shor t water co i l spout The Slag m at te -
.
-

overflows thro ugh a si mi lar spo ut i nto an oblo ng fore hearth 1 0 by 2 0 ft i n -

,
.

si d e . Thi s i s b uilt i nto an i ro n p an whi ch stands on rai ls r unni ng cro ss w i se -

i s li ned at the si des and ends w i th 9 i n of m ag nesi te br i ck and has a r em ovable .

,

roof composed of rai l bo und fire b ri ck arches H eat i s suppli ed th ro ugh t wo o i l - -

.

b ur ners on the center li ne of th e roof 6 i n back fro mthe fro nt whi ch req ui r e 7 , .
,

bbl Oil p er day; a sm

. all stack near the i nl et w i thdraws the gases The norm al .

dep th of the bath i s 2 5 i n ; of thi s 1 0 1 2 i n i s taken up by mat te as i t was fo und

— . .
,

th at such a m ass of m atte assi sted i n k eep i ng the fore h ear th i n goo d co ndi t i o n -
.

The waste slag ov erflow s i nto slag ca rs ; the m at te i s tap p ed i nterm i tt ent l y -

i nto co nver ter ladles A co m posi te samp le of slag shells prod uced i n 5 days .
-

gave: Au trace Ag oz p er ton Pb , and Cu p e r c e n t ; a n d t h e

.
,
.

dai ly 2 4 hr sam ple assayed Au trace Ag

-
. oz p er ton Pb and C u ,
.
,

p er c ent s how i n g t h at th e se p a r at.i o,n of m at te an d sl a g w a s sa t i sf a c to r y .

The av erage analy ses of a m o nth s pro duc ts showed : Slag Si 02 FeO
’
,

M nO Cao ZnO A120. Pb Cu p e r c en t .

,

Ag oz p er ton ; m atte 8 p er c ent of charge Fe

. Pb Cu .
,

Zn S p er c en t A u a n d A g o z p er to n ; l ea d b u ll i o n
.
, .

p er c en t of ch arg e. A u a nd A g o z p er t on T ,h e r e w er e p e r c e n t . . .

S on the charge; the coke used w as p e r ce n t A t yp i ca l a n a ly s i s of t h e z i n c .

mush someti mes floati ng On the matte i s : I nsol Fe CaO .

Zn S Pb Cu p er c e nt .

At Map imi an 80 ton reverberatory set tler recei ves the slag m atte from5
3 - -

ton ladles one to a blast fur nace , A ladle has a bai l at tached to the tr unni o ns .

whi ch serve as gli di ng p lanes when the ladle i s lowered on an i ncli ned track by
means of a crane i nto posi ti o n under the slag spout When filled wi th sla g -
.

matte the ladle i s p ulled up the i ncli ne transferred to a trough leadi ng i nto th e
, ,

1
Vail ,
E ng . Min J . 1 91 4, XCVIII , 4 68 .

1
E di tor, M et Chem E ng . . .
, 1 90 7, v, 4 0 .

1
Ri ce, E ng M i n J 1 908
. .
,
Lxxxvr, 3 73 .
 S M E LTI N G LE AD OR E S I N TH E BLAS T F URN ACE

l r and emp ti ed The advantages clai m

set t e , . ed for thi s arrang em ent are t hat

th e f urnace i s always accessi bl e that par ti al set tli ng takes pla ce i n the t n
5 o -
,

ladle and th at the amo unt of fume ari si ng near the f ur nace i s greatly r educed
, .

1 1 9 H andli ng of M atte — Th ere are i n op erati o n three m

.
eth ods of d i spo si ng

of th e li qui d m at te w hen i t i s tapp ed froma fore hearth or a reverberatory set -

t ler : I t i s collec ted i n sui table m olds and allowed to soli di fy i n a recei ver and ,

gra nulated or in a ladle and transferred to a converter

, .

IO
Bedl ul

23 E venly

FI G 256
.

FI G S . 2 55 and 2 56. — Ri chards m tte mold

a -
.

Fo rmerly mat te wa sl g pots Wi th smal l q uanti ti es of m

collec ted i n sa -
. atte

co ntai ni ng 3 5 p er cent Cu thi s i s sati sfac tory as such c ak es di si ntegrate q ui ckly

.
,

wh en exposed to the ai r and are easily broken Concentrated mat te wi th 30

, .
,

p er c ent C u an d ov
. er do es no t r e
,
adi ly fall to p i ec es ; i t i s to ugh and the br eak i ng
i s a ted i o us p i ece of work The slag p ot h as ther efore b een replaced by flat
.
-

mo l ds A si mple form of cast i ron mold i s gi ven i n Fi gs 2 64 and 2 65

.
-
. .
270 M E TALL URGY OF LE AD

As cast iron is readi ly attack ed by hot m atte a m old has to be clay w ash ed ,
-

before every tap and care must be had that all water has been expelled from
,

the clay by the h eat of the m old before thi s recei ves any matte as o ther ,

wise explosi ons are li kely to occur whi ch m ay scatter sho ts of red ho t m at te -

i n all di rec ti ons Cast i ron m olds are lik ely to be shor t li ved on acco unt of
.
-

cracki ng .

The Ri cha rds m old gi ven i n plan and sec ti on i n Fi gs 2 55 and 2 56 i s an

,
.
,

im proved form It consi sts of a steel plate p an bolted to one of cast i ro n whi ch
.
-

carri es a cast steel ri ng The mold has a cap aci ty of 7 58 cu ft and holds
-
. . . .

ther efore a li ttle over 1 ton of m at te when filled ; th e cake i s 4 ft 9 i n i n di ameter . .

,

4 i n thi
. ck a t the si des an d 7 i n a t th e c enter . .

I i
n

FI GS . 2 57 to 2 59 — Steel
. matte mold -

,
Selby Lead Works .

In do away wi th the necessi ty of breaki ng the cake of m

order to at te by

hand Kilbowen depressed i nto the li q ui d m

,
1
atte for a few seco nds a sta r

poi nted casti ng whi ch had been clay washed removed i t to allow the thi n coa t of -

adh eri ng m at te to so li dify and then depressed i t agai n l eavi ng i t i n po si t i o n for

,

1 2 14 m
— i n unti l the m. at te had soli di fied Af ter remo vi ng the star the cake of .
,

matte was hois ted from the mold and transferred to a heap where cooli ng ,

q ui ckly i t wo uld crack along the thi n walls m

,
ade by the star and fur ni sh ,

pieces that co uld be easi ly handled .

At the Selby W orks the m11

atte m old i s an oblong p an m ade of pressed steel ;
—
details are gi ven i n Fi gs 2 57 2 59 I n order to prevent the i m pac t of a st r eam
. .

of matte fromattacki ng the steel the mold i s charged wi th one or t wo shovel ,

fuls of crushed m atte before i t i s to be filled Tw o molds are placed across the .

1
E ng . Mi n . J .
,
1 9 1 0, x c, 1 00 5 .

1
Bennett , E ng . Mi n . J .
,
1 90 8, t xxxv, 2 5 2 .
272 ME TALLURGY OF LEAD

flat ti lti ng se c toral molds

ch ho ldi ng a cake of m
, ea at te w hi ch is 4 in thi ck and .

wei ghs about 2 00 lb The wei gh t Of the car wi th i ts m

. olds i s abo ut 6000 lb .

I n the m ore recent mo dels the spi der

i s a steel casti ng wi th 1 6 secto ral
frames whi ch hold the molds I n .

the draw i ng ch ai ns prevent the

molds from ti l ti ng too far when
they are b ei ng turned over ; i n th e
later mac hi nes a wrough t i ron yoke -

travel s aro und the p i n and the m old ,

st ri k es agai nst i t w hen i t is bei ng

dum ped The fore h ear th fro m
.
-

whi ch the m atte i s to be tapped has

a c urv ed spo ut so that the tap per

can enlarge or close the tap hole -

d
a wh i le t he m at te i s flow i n g A t som e .

works the matte flows from the

e
L

b
y
fore hear th i nto a sm
l
-
all bri ck li ned -

e
S cast i ro n box on wheels whi ch has
-

the c urv ed spo ut W h en th e m a t te

s
r .

a
i s to be tap ped the car i s run under
c
e
-
,
t

a
m
neath the c urved sp o ut the tap hole -

opened and the sp i der slowly ro ta ted

,

m
d
n wi th a hook ed h
a bar T h e a t t e . t us
runs successi vely i nto the pans as
o

m
t

a
they p ass alo ng fi lli ng th emi n p ar t ,

d ur i ng a revo luti o n of the sp i der .

0

g W h en the tap hol e i s clo sed -

t he ,

m
n
d oli
l
d s w i ll h a v e b een fi ll ed w i t h t h i n
layers of mat te whi ch are easi ly
n
a
H ,

broken A filled car i s h auled to

.

the yard where the matte cools

,

o
suffi ci ently.
i n abo ut 3 0 m i n t o .

allow d um pi ng the molds wi th a

.

chi sel p oi nted bar The til ted ho t

-
.

molds are clay washed ret ur ned t o -

thei r hor i z o ntal posi ti o ns and th e ,

car hauled back to the for e h ear th -

.

The c ak es of m atte h av e to be

crushed b efore they can be roaste d

or blast roasted The cak es are.

broken w i th sledges to siz es sui ted

for a rock breaker Thi s di scharges .

i nto rolls set to M i n wh i ch deli ver the m

,
. at te ei th er di rec tly i nto a trom mel
wi th i n holes or first i nto the boo t of a buck et elevator
-
.
When m uch .
 S M ELTI N G LE AD ORE S I N TH E BLAS T F URN A CE

crushi ng freq uently two pai rs of rolls for ro ugh

has to be done, there are used ,

i ng and fini shi ng so as to expedi te the work

,
.

As thi s m ethod of co mmi nuti ng matte i s exp ensi ve i nsani tary on account ,

o f dusti ng and co nnec ted wi th lo ss fro m the sam

,
e cause Granul ati ng has ,

S IDE vrs w F10 264 .

FIG 265
.

FIG S . 2 64 and 2 65 .
— Rhodes m at t e -
mld o .

FI G . 2 66 .
— Ki lker matt e car
-
.

taken the place of cr ushi ng i n a number of p lants In granul ati ng m atte i t i s .

,

essenti al to have a thi n stream to h av e w , at er r unni ng fro mone or pref erably ,

tw o flat no zz l es at a pr essur e of 60 1 00 lb and to h ave sufli ci ent set tl i ng ca

-

.
,

p aci ty to c oll ec t t h e gr anul es as w ell as th e sl i me th at i s for med Th e si ze of .

18
274 ME TALLURGY OF LE AD

granules m ay not exceed 16 i n as o th erwi se they do not ro ast sati sfac to ri ly It .

, .

was o nce held that granules of lead matte were hollow and decrepi tated upon
heati ng but thi s i s not generall y the case Consi derable care has to be ha d i n
, .

granulati ng as there i s much danger fromexp losi o n whi ch accordi ng to H utch

, ,

i nso n i s due to the low degree of difl usi vi ty( v eloci ty of tem
1
p er at ure ch ang )
e -

whi ch i s the rati o between th ermal co nducti vi ty and specific heat In granu .

l ati ng the man who regulates the flow of m

, atte stands behi nd a screen to be

pro tected fromspatteri ng matte .

Lead m at te used to be granulated at the Am eri can Sm elter Leadvill e Colo

1
.
, ,

The plant co nsi sted of three wood en tank s 1 0 ft lo ng 5 ft w i de and 6 ft deep .

, .
,
.

filled w i th water up to 1 0 or 1 2 i n fromthe top They were used i n ro tati on . .

,

tw o bei ng i n co nstant use whi le the th i rd w as bei ng cleaned up The water , .

from th e granulati ng tank s overflowed into a settli ng tank ; the am o unt of

Sli m e caugh t w as sm all For cleani ng up each tank had a num ber of op eni ng s .
,

i n one si de to di scharge the water and a gate i n one end to rem

, ove the granu ,

lated matte At the head of a ta nk j ust below the top was placed a 2 i n
.
, ,
-
.

pi pe flattened out at the end to throw a thi n wi de streamof water the pressure
, , ,

of whi ch ranged from2 5 to 30 lb p er sq i n The m at te w as ei t h er tap ped . . .

froma set tli ng p ot or po ured froman ordi nary slag p ot I n the la tter case -
.

i ro n bars were placed over the granul ati ng tank i n order to prevent the shell
fromfalli ng i nto i t and causi ng vi olent explo si ons The thi n streamof matte .
,

st riki ng the wa ter i ssui ng fromthe nozz le w as scattered i nto dropl ets and chilled ,

before i t fell i nto the water .

Ano ther plant worki ng on the sam e p r i nci ple under a pressure of 80 lb .

had tw o gr anulati ng tank s 1 2 ft lo ng 4 55 ft w i de and 2 ft deep di scha rgi ng , .

,
.
,
.
,

i nto one settli ng tank 1 2 ft lo ng 9 ft w i de and 2 ft deep whi ch had near th e .

, .
, .
,

di scharge end a canvas p ar ti ti o n to prevent any float m at te fro mb ei ng carr i ed -

The
J M a cA rth ur gr an
.ula ti ng tro ugh al so does sa ti sfac t ory work
wi th mat te and m ak es no float m atte -
.

At H um bold t Ariz Copper matte i s granulated wi th water whi ch i s deli v

1
,
.
,

ered fro ma 4 i n pi pe i nto tw o 3 i n p i p es under a co nstant pressur e of 60 lb

-
.
-
. .

per sq . in .

At E l Paso , Texas, lead m atte fromtw o reverberatory settler s used

‘
the ,

al ternat ely w as gr anulated unti l di rec t co nver ti ng r eplac ed the ol der m

,
eth od

of tr ea tment The two settlers wer e placed end to end at a di stance of 1 6 ft

. .

and 1 00 ft fromthe l i ne of blast fur naces

. The granulati ng p lant of one of t h e .

settl er s i s shown i n Fi gs 2 67 2 69 and the d etai l of m at te spo uts and w a t er .

-

no zzl es i n Fi gs 2 70 2 75 The m at te ( Pb Cu . Fe 3 1 5 p er cent and

-
. . .

1
E ng Mi n J . 1 909, 1.xxxv11 , 1 2 7 2

mm 43
. .
, .

1
Breth erton, Eng Mi n J , 1 89 7, . . .
,
.

1 H allett , Colo S chool M i n M ag , . . . January 1 914; E ng Mi n J 1 9 1 4 , xcvn, 3 74 ; Mi n

m
. . .
,

S ci ence, 1 9 1 4 , Lx r
x , 57; M in Sc Press, 1 9 1 4 , cv , 296 .

m 4 65
. .

Vail , E ng . Mi n . J .
,
1 9 1 4 , xcv ,
.

Easter, Tr A I . . . M . E .
,
1 91 5, LI I , 72 2 .
276 ME TALL URGY OF LE AD

Ag 1 2 oz per ton) w
. as tapped thro ugh a water cooled sp out i nto a l i ned cast
-

i ron box , 3 ft 8 i n by 6 ft 2 i n w
. hi ch served as
. . a t rap for m
. eta lli c lead
. Th e
box has two cast i ro n sp o uts whi ch co nduc ted the m
-
at te to the gr anul a ti ng

p i t . The two stream s of m at te were each cut by a do uble spr ay of w ater ,

211 in. wi de and % 6 . p i

i n thi ck , i ssui ng from
pes at a pressure of 1 00
lb per sq i n The granules were collected i n a p i t co nstantly filled wi th wa ter
. . .
,

raked out wi th hoes wheeled to rai lroad cars and hauled to the Go dfrey fur
, ,

naces of the H unti ng to n H eber lei n plant The overflowi ng granulati ng w ater
-
.
 S M ELTI N G LE AD ORE S I N TH E BLA S T F URN ACE

passed thro ugh settli ng tanks I n roasti ng no difl erence was no ti ced i n the .
,

behavi or of granulated fromthat of crush ed matte .

At H erculaneum Mo a plant for granul ati ng 1 00 tons m

1
, at te p er day went
.
,

i nto op erati on on M arch 1 1 9 1 5 The m a t te fro mfo ur b last f ur naces i s col ,

.

lected i n m ovable fore hearths 6 by 4 ft and 2 2 i n deep tapp ed i nto 6 cu ft -

, . .
,
-
. .

i ro n ladles transported by a 5 ton overhead elec tri c crane po ured i nto a barrel
,
-

S hap ed ro ta ti ng rec ei v er of bo i ler i 1 0n and granula ted fromthi s by tw o super ,

posed w ater j ets ; the mat te granules are collec ted i n a p i t and transferred by -

means of a dewater i ng drag conveyor to a car Fi gs 2 76 2 80 show the detai ls — -

. . .

Th e rec ei ver 77 by 1 2 0 i n insi de i s li ned wi th 9 i n of m

, ag nesi te bri ck and t o .
,
.
,

tat ed froma 50 h p m o tor I t has at each end a 2 0 i n Openi ng At one end

-
. . .
-
. .

are t w o oi l b urner s for k eepi ng the m

-
at te fl ui d ; th ey are served by ai r und er a

p r ess ur e of 3 0 lb p e r sq i n a n d co nsu m e i n.2 4 hr 2 5 g

0 al o i l of 1 8— .2 0 B é .
, . .
°
.
,

or 2 2 5 gal oil p er ton of granulated mat te I t has been fo und necessary to

— . . .

have an oxi diz i ng flam e i n sp i t e of the fac t that i t has a tendency to oxi di ze so m e

of the Fe whi ch i s li k ely to forma floati ng scumi nterferi ng wi th the po uri ng

'

, .

At the o ther end i s an 1 8 i n steel fl ue connec ted wi th the bagho use A swi ngi ng -
. .

hood covers the charge Openi ng and co nducts fumes i nto the blast fur nace flue -

leadi ng i nto the bag ho use ; i t i s s ung b ack when a ladl e of m atte i s to be po ured w
i nto the recei ver The m a t te i s di scharg ed fromthe recei ver th ro ugh an O p eni ng
.

2 by 8 i n over a sp o ut deli v er i ng i nto a po ur i ng box of sh eet i ro n li ned w i th

.
-

fire br i ck
-
The box 1 8 by 36 i n and 1 8 i n deep i nsi de has at the fro nt a
.
,
. .
,

slo t 2 by 8 i n
, deli v eri ng i nto a cast iro n spout whi ch i s sli gh tly deflec ted i n
.
,
-

order that i t may meet the hor i z o ntal j ets of water at an angle of 70 or The
end of the spo ut i s 6 i n above and 1 2 i n i n fro nt of the up per w ater noz z l e
. .
-
.

Th e m at te b uil ds up i n the box but l eaves open a channel abo ut 3 i n wi de ,

. .

The granula ti ng w ater arr i ves und er a head of 40 ft i n tw o 2 i n superp o sed .

-
.

pi pes wi th nozzles by 3 i n placed 5 i n apar t ; about 1 00 gal water per mi n .

,
. . .

are req ui red The streamof m atte i s so r egulated that the upp er jet of w
. ater

breaks i t and that the lo w , er cools t he granules suffi ci ently that on striki ng the

mai n body of water they are cool enough not to cause an explosi on A stream .

of matte 2 34 i n i n di ameter correspondi ng to . cu ft per m i n has been fo und ,

. . .
,

to work sa ti sfac tori ly If the st reami s a li t tl e larger the granules are too
.
,

bi g; if a li t tle sm al l er the m at te i s li k ely to chi ll b efore i t leaves the po uri ng

,

bo x . A hot m a t te f urni sh es finer granul es of gr eater uni for m i ty th an one that

i s cool ; wi th a good produc t 75 p er cent wi ll pass t hro ugh a screen w i th open ,
.

i ngs M6 i n i n di am eter A screen analysi s shows : on M i n

. 0
5 p e r c e n.t o n . .
,

— —
%6 4 on ,
1 4 on 5 t hro u gh hi
-

s i n ,
2
4 p er c en t Th e g ra n nh s ,
. .

are collec ted i n a co ncrete tank 1 7 ft long by 71 4 ft w i de w hi ch has a floor

m
.
,
.
,

pi ng at an angle of 30 and li ned wi th 1 i n cast i ron plates ; they are r emoved °

-
.
-

by a dewateri ng drag conveyor placed to one si d e and out of the li ne of the -

str eamfromthe nozz les The conveyor i s dri v en at a sp eed of 30 ft p er m . in . .

by a 1 0 h p mo tor through tai l and i dler sprocket wheels bo th bei ng under

-
. .
-

water The co nveyor runs i n a sec ti o nal cast i ro n tro ugh 1 5 i n wi de and 4 i n
.
-

,
. .

1 Li nden Smi th -

,
Tr A I . . . M . E .
,
1 91 6, LVI , 67 1 .
278 ME TALLURGY OF LE AD

deep ; drai nage i s assi sted by no tchi ng the co nveyor fli gh ts al ternately i n the
center and at the ends to such an extent th at the granules carry o nly abo ut 5
e r c en t w a ter Th e ov erflow fro mthe granula ti ng basi n passes thro ugh a V
p . .

shap ed settli ng box whi ch collec ts the coar ser par ti cles of the fines and t hen
-

, ,

t r avels thro ugh O ne of tw o seri es of co nnec ti ng set tli ng tanks the last bei ng ,

provi ded wi th a fil ter of ex celsi or Some lead set tles i n the recei ver is .
,

po ured i nto a ladle and molded Any lead go i ng over wi th the m , at te i s q ui ckly .

no ti ced i n that i t sp ut ters and dances on the surface of the water .

Granulati o n req ui r es four m en p er shi f t for Op erati ng the r ecei ver and the

crane; i t costs 5p e r to n T h e for m e r m e t ho d of co m m i nu ti o n w a s t o

. ta p th e ,

matte fromthe fore hear th i nto slag pots to d ump these after cooli ng to break - -

, ,

the cones of m at te wi th sledges and to t ranspor t the h and brok en m at eri al ,

-

to the cr ushi ng di vi si o n w here i t was reduced to M i n si ze H and br eaki ng ,

-
. .
-

and transpor ti ng cost a ton crushi ng and screeni ng maki ng a ,

to tal of granulati o n therefore eflects a savi ng of

‘
p e r to n .

Co nver ti ng m atte i s di sc ussed i n § 1 85 .

1 2 0 H andli ng of S lag
.
— Tw o m ethods are followed i n di sp o si ng of th e .

large amounts of slag made i n a modern blast furnace; one i s to have large
rec ei vi ng po ts whi ch are poured the o ther i s to granulate the slag ei ther di rect ,

fromthe fore hearth , or preferably froma recei vi ng pot Occasi o nally cakes
-
.

of slag are allowed to cool on the dump broken and crushed to a si z e sui ta ble , ,

for rail road b allast Granulated slag frequently serves for the same purp ose . .

Casti ng m achi nes are sui t able i f th e S lag has to be resm

1
el ted as th ey fur , ,

ni sh a produc t whi ch i s easi ly handled and well sui ted for furnace ch arges .

I S lag Cam D escri p ti ons of a few typi cal waste slag po ts b ui l t by the
.
— -

Colorado I ro n Work s of D enver Colo m ay serve as exam ples ,

.
, .

1 S pheri cal S elf dum

. i
p g n P ot — T h e pr i n c i p al p ar
-
ts of t h i s p o t s how n i n ,

Fi gs 2 8 1 2 83 are a car co nsi sti ng of a steel fram

.
—
, , e wi th 1 2 i n wheels on a 2 4 i n
,
-
.
-
.

t rack and a central braki ng m

,
echani sm ; w t o heavy cast i ro n r unways curved - -

at the end s wh i ch for mthe paths on whi ch the segm

, ental cas ti ngs at the end s

of the p ot travel ; a cast i ron self d umpi ng spheri cal p ot 4 1 i n i n di ameter of - -

, .
,

9 cu ft c
. ap a c i t y . 1 to n of sl ag ) p i vo t e d i n su ch a m a n n er t h at i t w ill ,

stand upri gh t when em p ty and ti l t over when filled wi th slag ; an upri gh t p os t ,

wi th movable cross pi ece whi ch fits i nto a recess near the ri mof th e p ot and -

holds i t i n i ts upri ght posi ti o n Self dumpi ng po ts are si mple i n co nstr uc ti o n .

-

cheap and work sati sfac tori ly e g at M o nterey Mexi co when everyth i ng i s
, , . .
, , ,

i n good order If however through an acci dent the cro ss pi ece holdi ng the
.
, ,
-

f ull p o t i n posi ti o n beco mes di splaced a seri o us acci dent m ay happen Thi s i s , .

the reason th at m o st pots have a ti l ti ng mechani smwhi ch com pletely co ntrols

the d um pi ng .

2 Cool S lag pot w

. it h Wormgear — -
The pri nci pal parts of thi s p ot Fi gs 2 84 -
.
,
.

2 86 are sim
,
i lar to tho se of th e prec edi ng one The fram e i s b ui l t of steel rai ls ; .

1
B raden, Tr A I . . . M E . .
, 1 896 , xxvr, 5 1 .

M i n S c Press 1 90 7 x crv, 2 8 2
Austi n, . .
, , .

H ofman
“ Metallurgy of Cop per, 1 9 1 8,
,
”
3 1 6, 3 1 7 .
 ME TALLURGY OF LE AD

FIG 284 .

F1c 28 6
.

FI G S . 2 84 to 2 84 — Oval
. slag car
-
wi t h wo rmgear
-
.
282 ME TALLURC Y OF LE AD

wheels , g
. Two bri dge bea -
m lyi ng transversely across the frame a serve
s, h, , ,

as sup port for frame h ,

'
, whi ch carri es central p i n socket m i n whi ch p i n n -

, , , ,

is m The sw i ngi ng fram

'
ad e fast by nut n ,
. e co nsi sts of ch annel i ro ns i i ( held -

F1 G . 2 90 — Si de
. elevat i on .

FI G . 2 goa — Plan
. .

END ELEVAT IO N
recur f or ner-oven
-

FIG 291 .

FI G S . 291 and 2 9 2 .
— Double bo wl car
-
.

ap art by central block s j j i n w hi ch are th e swi vel eye and end blocks j j ) -
'
-
, , ,

and beam s k k ( resti ng on the channel Iro ns) ; the l at ter have on thei r under
,
-

si de the b eari ngs of trunni o ns l l of th e til ti ng po ts A A

, These are pi vo ted
,
-

, .
284 ME TALLURGY OF LE AD

the tro ugh water whi ch arri ves i n fl ume d i s di scharged at the si de
. The , , ,

t hro ugh clo sed hori zo ntal box e i nto i ncli ned box j whi ch i s open at the
’

, , , ,

top The am . o unt oi water req ui red i s gal p er m i n Very l i

'

ttl e st eam . .

i s generated and hardly any noi se i s m ade provi ded no m atte i s carri ed 05 ,

wi th the slag as matte com i ng i n co ntac t wi th water causes explo si o ns

,
Th e .

cast iron plates i n the tro ugh are worn thi n i n abo ut 6 mo nths The elevator is
-
.

dri v en by a 4 h p Lefl el m i ni ng w heel The bel t traveli ng at a speed of 2 50

-
. . .
,

ft p er m
. i n i s 8 i n wi de and 8 p ly and lasts abo ut a y ear ; the buck et s are
. .
-

of m all eabl e cast i ngs and h ave i n holes i n the end s for the water to drai n -
.

ofl The slag granul es are sm

. all eno ugh to pass a M i n si eve; w hatever par ts -
.

th ey stri k e w i ll be q ui ckly worn out i f not pro tec ted by i ro n p l ates ,

.

' '
Si dee 2 l h lok

p lant , H anauer W orks, Salt Lake Ci t y, Utah

—
F1 os 2 9 3 and 2 94 Terhune slag g anulati ng
r
-
. . .

The M acArthur granul ati ng tro ugh , by the Canadi an Cop per formerly used
Co Sudb ury Ont i s sho wn i n Fi gs 2 9 5 30 1
.
, ,
— The tro ugh a i s m
.
, o unted on . .
, ,

wheels so that i t can be easi ly p ush ed to one si de when the movable fore hearth ,
-

b rec ei vi ng the slag m

, at te m i x ture fro mthe blast f urnac e c has to be ex changed
-

, , ,

an op er a ti o n taki ng abo ut 1 0 m in The tro ugh co nsi sts of t wo p ar ts the granu .

,

lator p rop er d and the tro ugh c whi ch conveys the granulated slag to the
, , , ,

mouth of an underground flume ( not shown) 50 ft lo ng whi ch di scharges i nto a .

,

drai nage p i t w hence the slag i s rai sed by means of a b ucket elevator and emp ti ed
-

i nto rai lroad car s The granul ator ( 1 co nsi sts of a tro ugh shaped casti ng f
.
, ,
-

, ,

wi th si de flanges i nclosed by a cast i ro n j acket g of si mi lar shape so as to leave

- -

, ,

aw ater sp ac e h betw een them

-
To the upper end of the j acket i s bol ted the
, ,
.

back plate wi th fl anged sp o ut i Thro ugh the flanges pass bol ts j the jo i nts ,
.
, ,

bei ng made water ti gh t wi th r ubber gaskets The granulati ng water whi ch i s

-
.
,

the blast f ur nac e water j ack et overflo w and has a tem perat ure of about 6 5 C -
°
, .
,

enter s the water spac e at k r i ses thro ugh the openi ng I and bei n d eflected by
g
-

, , ,
 S M ELTI N G LEAD ORE S I N TH E BLAS T F URN ACE

down under i t i n a thi n stream The slag flows i n a si m

the spout , i , passes i larly .

thi n streamover the spo ut i and slag and water co m ,

e i nto q ui et and sm
, oo th
contac t bo th flowi ng i n the same di rec ti on There is no steam splash or
,
.
, ,

noi se and no danger of explo si o n

,
As the slag i s not drop ped i nto the water i t
.
,

does not adhere to the tro ugh bo tto mand forma sem i li q ui d ball sure to ex
- -

plo de Th
.e granu la ted slag i s un i forml y coa rse A bo u t 1 00 t o ns of S lag .

were granulated wi th 60 gal of water per mi n havi ng a head of 1 6 ft ; but

. .
, .

S IDE VIEW

BACK PLATE

WM M mM M M
mm m
t J oI
m
-

h su u
l ure M. pc llq In.
.

DETAILS
FIG S . 29 5 to 30 1 —
. McArt hur granulati ng trough .

the capaci ty of the granulator i s half as great agai n as thi s The ap p aratus .

is also sui ted for granula ti ng m atte if thi s i s tapped i nto a recei ver and po ured ,

in a thi n str eamon to the spout .

Ordi nari ly slag i s granulated by havi ng a flat jet of pressure water i m pi nge -

upon a thi n st reamof slag as i s usual ly the case wi t h m a t te At the M o nd .

Ni ckel W ork s Vi c tori a M i nes Ont the arrangem

,
1
ent s for granula ti ng slag and
,
.

conveyi ng the granules to the dum p sho wn i n Fi gs 30 2 30 5 were i n Op erati o n

—
, .
,

before the plant w as di smantled The slag com i ng fro mthe set tli ng fore hear th
.
-

1
Hi xon, E ng . Mi n
. J .
, 1 906, 11 11111111 , 553 .
286 ME TALLURGY OF LEAD

i s granulated by eans m of water flowi ng i n a 3 i n pi pe under a head of 2 0 lb

-
. .
p er

sq i n , and is sui ng fro

. . ma no l
zz e, 94 by 1
3 5 i n . and 9 i long Granula ted si ng
n . .

and w ater tr avel for 7 ft 9 i n . .

thro ugh an i ncli ned 8 i n ca st -

.

i ro n pi pe of whi ch the low er

si de has a li ni ng of m anga nese

steel and enter o ne leg of a

Y sh ap ed
-
casti ng I n the .

o ther leg i s p laced a p i pe 2 946

1
,

i n i n di am eter wi th m anga

“
.

nese steel no zzle 1 9

- 1 in in .

dia meter The p i p e i s con

.

nected wi th a 5 i n m
.

ai n w
s
u hi ch -
.

recei ves fro m a cro ss com

a
r
a -

po und duplex pump 1 000 gal

p
p
a .

g
n
water per mi n at a p ressur e of .

i
y
e 1 50 lb per sq i n . The jet of . .

pressur e water stri kes the mi x

v
n -

t ur e of granul es and w
c
at er and ,

n
a dri ves i t thro ugh the manga
g nese steel -
li ni ng of a 5 i n -
.

i
n
t
a cast i ro n di scharge pi pe whi ch
- -

carri es i t to the dump T hi s

l
u
n .

a
r
g discharg e p i pe is leng thened as -

the dum m
-

l
g
a
s
p grow s T w o e n .

1
1
on a sh i f t at tend to the ap

parat us whi ch handles the slag

fro m a blast fur nace trea ti ng
i n 2 4 hr 2 50 to ns charge . .

Si m ple slag and mat te

2 g r a n u l a t i n g app aratus for
sm
0
3
all siz e f urnac es h ave been
-

sk etch ed and descri bed by

s

Barbo ur 1

moval of Dust and

.

121 . Re
Fume fromFurnace Buil di ng .
1

blas t furnace smel ti ng — In a

p l ant d ust a nd f ume ar i se fro m

the handli ng of fi ne m ateri als ,

fro mtemporary openi ngs i n a

f ur nace and from hea ted and ,

mol ten materi als .

D ust i s set free mai nly on t he ch argi ng floor and to som e ex tent also a sm all,

1
E ng . Mi n
. J .
5, x crx , 2 39
,
1 91 .

1 M essi ter, Mi n S c Press, 1 908,

. . x cvn, 2 6 .
288 ME TALLURG Y OF LE AD

l g i s the Tappi ng H ood of Messi ter whi ch was fi rst used at Arka nsas Valley
and s a -
‘

plant Leadvi lle Colo and later at E l Paso Texas and o ther places The
, ,
.
, , ,
.

hood shown i n Fi g
, co nsi sts of a sheet i ro n box ap proxi mately cub i cal
.
—
s 308 3 1 2 , -

and Open at top and bo t to m whi ch r ests on a rec tang ular angle i ro n suppo rt
,
-

1
Eng . Mi n
. J .
,
1 900, Lx xx, 31 7 .
 S M EL TI N G LE A D ORE S I N TH E BLAS T FURN ACE

havi ng the si des clo sed wi th pi eces of sheet i ro n provi ded wi th handles The .

back of the box i s extended to meet the j ack ets surroundi ng the tap hole; the -

front has the for mof a truncat d p yrami d wi th si des ex tendi ng to near the back
e

of t h e hood and co nvergi ng toward the tap hole -

. A p i pe 2 4 i n i n di am
, . eter and
— 0 ft lon pla c d n t h hood f u ni h ll t h dr ft n c ess ar t c arry off
35 4 .
g , e o e , r s es a e a e y o
19
290 ME TALLURG Y OF LEAD

the fu mes Acro ss the

front of the box li es a pi pe to serve as a gui de for the
.

tappi ng bar and p l uggi ng rod -

The angle fram e carri es tw o swi ngi ng doors wi th -
.
-

r i n slo t i nterveni ng whi ch perm

-
. i ts the tapper to follow the ri si ng of the sla g
i n the p ot The w ork of the hood i s astoni shi ngly efi ecti ve
. .

At present si m i lar hoods are placed everywhere around a blast furnace

where f umes ari se; the pi pes fromseveral hoods end i n a mai n whi ch i s connec ted
wi th an exhaust fan deli veri ng dust and fume i nto a bag ho use At Mi dval e .
,

U tah the d ust and fum e col lec ted m onthl y fromfo ur blast f urnaces i n a
l
,

bag ho use am o unted to 2 2 tons wi th an assay value of Pb 4 2 and Zn 2 2 p er -

cent The collec ti o n of f ume on the furnace floor i s therefore not only a
.

sani tary m easure but form s a profitab le Operati o n ,

.

Thi s di spo si ti on of the coll ec ti ng app aratus aro und a fur nace at the Selby
Lead Works has been show n i n Fi gs 1 9 7 and 1 98 . .

The detai l of ano ther plant i s sho w n i n Fi g 3 1 3 The b last f urnace ( Fi g s . . .

2 4 0 and 2 4 1 ) has a lead well at the si d e and tw o for e h ear th s i n seri es at th e

- -

fro nt Th e lead well has a hood extendi ng over the basi n and sp out ; the hood
.
-

balanced by counter wei gh ts ends i n a pi pe whi ch passes telescope fashi o n over

-

,
-

the stati o nary branch pi pe of th e exh aust m ai n The fum es ari si ng fro mthe
-
.

matte pan when the fore hearth i s bei ng tapped are taken care of i n a si mila r
-

,
-

way; the same i s the case wi th the overflowfromone fore hear th to the other -
.

The hood for the waste slag p ot covers the pot as well as the spo ut del i veri ng -

the slag The co ntrast of the atm

. osp here i n an old p lant and a moder n p ro
vi ded wi th proper ventil ati ng facili ti es i s stri ki ng to the eye; the di m i nuti o n of
cases of lead poi so ni ng i s very evi dent and as shown above the am
-
o unt of , , ,

f ume recovered i n the bag ho use pays for the cost .

1 2 2 Blast Furnace Plant

.
— So far there have been di sc ussed the detai ls of
the roasti ng apparat us and operati o ns and the str uc tural feat ures of the blast ,

furnace and i ts accessory apparatus There remai n to be consi dered the area .

of plant power li gh t water etc i n one word the engi neeri ng features and the
, , , , , ,

co st .

The only newplant whi ch has m odern methods of handli ng materi al s i s that
of the B unker Hi ll and Sulli van Mi ni ng and Concentrati ng Co at Kellogg .
,

I daho ’
The detai ls of a m
. odern smelti ng plant planned by H V Croll of the . .

“
Traylor E ngi neeri ng and M anufac turi ng Co Allentown Pa for B lank
”
.
, , .
,

wi ll gi ve an i nsi gh t i nto the leadi ng features and the cost of a smel tery meeting
present requi r ements .

1 B unker H i ll S i lver lead S m

. eltery
‘—
A plan and ver ti cal sec ti o n are gi ven -
.

i n Fi gs 3 1 4 and 3 1 5 ; detai ls of the W edge roasti ng k i ln and the D wi ght Lloyd

.
-

si nter i ng m achi nes h ave been sho w

—
n i n Fi gs 1 69 1 7 1 and tho se of th e blast .
,

furnace i n Fi gs 1 84 and 1 85 The plant whi ch has a cap aci ty of 600 to ns ore p er
. .
,

day covers an area of 30 acres ; i t i s b ui l t on a terraced si te

,
The ores are sam .

Pri vat e notes, June , 1 91 6 .

Edi t or, E ng Mi n J , 1 9 1 6, cr, 868, p lan, di

. . . mn i oned
e s .

Labart he, M i n S o Press, 1 9 1 7, cx rv, 1 55 . . .

D esi gned by Bradley , B rufi , and Labarthe , San Franci sco, Cal .
292 ME TALL URG Y OF LE AD

and 4 00 ft long , i nto

. a preci pi tator havi ng a mpad ty of
Co tt rell cu ft . .

gas p er mi n . The prod uc t of the D wi gh t Lloyd m

-
achi nes i s collected i n hOpper

bot t o m steel ears and

unl oa ded i nto co ncrete
charge bi ns There are -
.

provi ded 2 4 charge bins -

at the w est end of the

plant each wi th a capac ,

i ty of 3400 cu ft ; of the . .

bi ns 8 bui lt of co ncrete, , ,

are for roasted m aterial ;

8 b ui l t of ti m, ber for ,

li mestone crude ore slag , , ,

i nterm edi ary products ,

etc ; and 8 also of ti m

.

y
r . ber , ,

tw
m
for coke Each bi n has
o di scharges provi ded
s
.

d
a wi th arc gates ; under -

ea ch g a t e are hopp er

scal es of 4 tons capaci ty .

The wei ghed charges are

l
l
i

H held i n the hoppers until

—
th ey are deli vered to the
k
L n
A u b last f urn a ce cha rgec ars .

N B
O I
Besi de the 400 tons coke
T
held i n the 8 bi ns there
.

5
1 ,
3
i s provi d ed back of the
d
n
a c h a r g e b i n s a storage -

place for 3000 tons coke .

Blast Furnace Depart »

m ent — The b ui ldi ng, 80

by 2 1 6 ft i s of steel con .
,

st r uc ti on I t i s provi ded .

wi th a ao ton 4 motor - -

traveli ng c rane w hi ch also

serves the r efi nery ; con

tai ns t hree blast f urnaces ,

4 2 by 1 80 i n w i t h un de r .
,

floor down takes show n -

i n Fi gs 1 84 and 1 85 . .

T h e c h a r g e c a r s are -

hauled by 4 to n electric -

l oco m oti ves to the feed

floor and bo tto mdi scharged
,
-
The fore hear ths of cast steel are handled
.
-

,
-

by means of the crane ; the recei vi ng po ts for the lead bulli on are t ransferred
 S MEL TI NG L E AD OR E S I N TH E BLAS T F UR N ACE

by th e crane to th e refinery ; the waste slag goes i n steel collecti ng po ts of

1 30 cu ft capaci ty to the dun ; a sk ull breaker red uces the return slag
. .
m - -

t o sui table si ze ; th e gases enter a settli ng flue whi ch deli vers i nto a m ai n -

fine 600 ft long whence they pass i nto the fan ho use Thi s contai ns tw
,
.
,
o .

elec t ri call y dri ven fans each of -

cu ft capaci ty one bei ng held i n , . .
,

reserve The fan forces the gases i nto a bag house 56 by 1 30 ft of bri ck
.
,
.
,

an d steel const ruc ti on Beneath the t hi m ble floor are 1 2 bay s ; above i t three
.
-

cha mbers each wi th 400 bags Leaving the bag house the gases are carri ed
, .
,

off by a stack rs by zoo ft .

P a p er Plant — Thi s i s housed i n a bri ck and steel b ui ldi ng 35 by 40 ft It .

,

rec ei ves an alternati ng current at 2 2 00 vol ts Blast i s furni shed by two .

I ngersoll Rand turbo blowers w -

i th a capaci t y of cu ft ai r p er m i n at . . .

a pr essure of 4 8 oz p er sq i n ; the blower s are gea red to tw . o General E lectri c . .

zoe h p .i nducti o n m
. otors T w o 75 kw m otor generator sets furni sh the .
-
.

di rect current for the trolley locom o ti ves and elec tri c cranes ; one m o tor serves
as an auxi li ary uni t .

General Equi pm — Thi s consi sts of a bri ck assay ofi ce and laboratory

m
ent -

bui ldi ng 4 6 by 4 6 ft a ware house m

,
achi ne shop dry ho use c cc hi gh pres
.
,
-

,
-

,
-

, ,
-

sure fire system com -

plete electri c system and sewerage
, , .

R efini ng Departm ent — It for m s an ext ensi o n 1 05 by 1 08 ft of the bl ast ,

.
,

funace b ui ldi ng ; co ntai ns tw o So ton so fteni ng f urnaces and fo ur so ton -

,
-

des il veri z i ng k ettles bo th served by the zo ton crane of the blast f ur nace
,
-

dep a r t m ent ; t w o So ton refini ng furnac es 1 0 ft below th e k ettles ; and fo ur

-

, .

merchant kettles fromwhi ch the lead i s rai sed by centrifugal pumps i nto Mill er
-

mol di ng machi nes Fi gs 599 and 600 The zi nc si lver crusts are treated i n
,
. .
-

the si lver gold refinery a bri ck bui ldi ng 60 by 82 ft

-
whi ch contai ns ei ght , , .
,

Faber du Faur r etor t f urnac es tw o cupelli ng fur nac es one si lver refini ng fur , ,
-

nace and a sulphuri c aci d parti ng p lant

,
The si lver sulphate i s deco m posed
-
.

wi th metalli c copper and the copper sulphat e soluti on concentrated and crys ,

talli zed i n th e c0p p er sulph ate b ui ldi ng .

2 .Blank S i lver lead S w —

atery The outli nes of thi s plant i ntend ed to
-

trea t 300 tons sulp hi de lead ore i n 2 4 hr are gi ven i n Fi gs 3 1 6 and 3 1 7 The ore . . .

arri ves on the upper t rack i s wei ghed and unloaded on to a b el t co nveyor ,

whi ch del i vers i t to the crushi ng and samp li ng di vi si on The sampled ore i s .

conveyed i n a si mi lar manner to the recei vi ng bi ns of the oil i gni ted D wi ght -

Lloyd 4 2 i n si nteri ng m achi nes fro mwhi ch a conveyor i ncli ne carri es the
-
.
,
-

blast roasted prod uc t to the si ntered ore bi ns In li ne wi th th ese are the bi ns -

.

for coke and li m esto ne The charges m ade up fro mth e b i ns are haul ed to the
.
, ,

feed floor of the two blast furnaces 4 2 by 1 2 8 i n at tuyeres whi ch are si m

-
i lar ,
.
,

to those of Nor thpor t Wash shown i n Fi gs 1 80 1 83— The lead b ulli o n go es

, .
,
. .

to the drossi ng plant ; th e cakes of m att e are brok en froma boo mderri ck the -

fore hearths hauled to the d ump are handl ed fro man overhead crane; waste
-

, ,

slag cars are conveyed to the d um p and poured ; waste gases fro mthe blast
roasti ng di vi si o n pass i nto a b alloo n flue and are cl eaned i n a Co t t rell
p reci p i ta t
i ng plant before th ey are carri ed off by th e stack The plan shows the loca .
294 ME TALL URGY OF LE AD
296 ME TALLURGY OF LE AD

Power Plant ,
Buildi ng ft

2 N o 7 Roots blow
. ers lb .

2 engi nes, re s Tangye auto mati c cut 06 , -

Eri e engi ne

co mp l ete

1 blast p i p e 60 i n di a . mX . 1 4 o ft
2 connect i ons 2 4 -
ft blowers to p i pe
. .

2 24 i n blast gates
-
.

2 belts 1 2 i n X 80 ft each 6 p ly . .

1 engi ne 1 1 X 1 5 i n , Tangye auto . mati c 70 h p . .

1 generator 2 2 0 volts, 50 k . v a .

rs wi tchboard and

lb .

Frei gh t to NewYork
Pack i ng
E rect i on
Buildi ng 55 X 85 ft

Boil er Pla nt, Buildi ng ssx ssft

3 b o il ers, 72 ft .
, 1 25 hp .

1 B F pu p ,
. . m in
Pi p i ng to engi nes
Bri ck for boil ers :
Red,
Fi re 7, 500 .

,
Cubi c yards sand, 2 1

Barrels ment 2 1 ce ,

Bushels li me 00 ,
1

lb
.

Frei ght to N e wYork

o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o
 S MELTI NG LE AD OR E S I N TH E BLAS T F URN ACE

Drossi ng Plant, Buildi ng ft

1 ket tle, 8 ft di a . meter

Iron work for setti ng .

1 00 bulli on mlds o

1 -
in . centri fugal p um p and h
5 p -
. . motor
1 ch ai n block for sa m e

Floor p lat es, cast i ron .

1 Dormant scale , No . 1 04 6

Fi re and red -
bri ck for k et tle setti ng

Fi re clay, lb
Fo b . factory
. . . lb
.

Frei ght to N ewYork

S i nteri ng Plant, Build i ng 1 40 ft

2 D L si nt eri ng
. .

2 5 h
0 — .
p . motors for fans
1 belt conveyor, 1 6 i n . X ros ft
1 elevat or, 1 2i n X 50 . ft B. .

1 5 h
0 — .
p . m otor to dr i ve conveyors, elevators, and si nt eri ng

10 belt feeders , 24X 6 ft

10 bi n hop p ers and gates

1 ai r co mp ress o r belt dri ve,

1 oil tank , 8 in X % .

1 1o hp -
. . mot or for co mp resso r

2 ta nks, 24 ft
Pi p i ng, valves and fit ti ngs

1 waste gas flue -

, 5 ft di a. mete r, i ncludi ng connecti ons, machi nes
to fans
1 1 6 in -
. conveyor tri p p er over bi ns .

1 16 -
in . conveyor t ri p p er over 3 .

2 E vans sp eed cones .

2 hopp ers o ver s . machi n e 6 X 6 ft

1 ai r recei ver, 36 X 96 i n

F rei ght to Ne wYork

P acki ng
E rect i on
B ui ldi ng 7c x 1 4 0 ft i ncludi ng bi ns .
298 ME TALLURGY OF L EAD
’

Ofi ce eq ui p mnt e .

Total

Assay ofi ce equi p mnt

e

Total

1 Dorman W . scale, lb
.

Ofi ce equi p mnt e

00

1 la the, 24 i n X 1 0 ft
.

1 bolt cut ter up to 1 36 in

1 grmd t s one 1 , 000 1b
.

r blacks mi th shop , 2O X 30 ft

1 anv11, 6o lb
1 set B S tools
. .

Total
Frei ght
Packi ng
Erecti on

m
ta - 0°

Yard
2 chargi ng cars 1 4 , 000 1b
.

1 sup p ort for sa me .

I ron work for ji b crane

Tracks and

1 RR track
.

Tracks and s wi tches . Bins to furnace

10 wei ghi ng hop pers for bi ns .

1 conveyor 2 80 ft long for si ntered

. ore

1 balloon flue and sup p orts, 1 2 X 4 00 ft

1 stack , 8 X 1 so ft

Total f o b factory
. . .

Frei gh t to N ewYork

E recti on
 M E TALLURC Y OF LE AD

Physi cal d rds for lead blast furnace coke have not been formulated
stan a -

as yet A c ubi c foo t of good coke pi led loosely wei ghs about 2 7 5 lb ; i t has
. . .

abo ut 50 per c ent of c ell space and an ul ti m ate co m pressi ve strength of 800
.
-

1 000 lb p er sq i n . Coke fro m by produc t ovens whi ch i s harder than

. .
-

that fro mt he bee hi ve has to be used i n sm all er pi eces than bee hi ve coke as
-

,
-

large pi eces b urn too slo w ly i n t he lead blast furnace .

T he am o unt of fixed carbo n of coke usual ly i ncreases wi th the hardness and ,

t hi s wi th the ti m e and tem perat ure gi ven to the operati on of coki ng The .

percentage of volati le hydrocarbon i s low usually i nsi de of 2 p er cent Coke , .

wi th over 2 p er cent V H C has been no ti ced to favor creepi ng up of hea t . . .

-
.

i n the furnac e The am ount of ash vari es fro m1 0 to 2 0 p er cent ; i t i s usually

. .

nearer the fir st figure Addi ng 2 p er cent V H C to an ash co nt ent of . . . .

-

.
-

say 1 2 p er c ent
,
gi ves by di flerence the R C at 86 p er cent Table 58 gi ves the
.
,
. .

proxi mate analyses of some i mportant brands of blast furnace coke .

TAE LE 58 — Pnox 1 11 A 1 E .
'
AN ALY S E S or CortE US E D 1N LE AD D1 srnrcrs

O O O O O O O O O O O O O O O O O O O O O O O

In Tabl e 59 are gi ven ana ly ses of coke ash -

.

TAB LE — AN ALYS E S or CO KE ASH

59
-
.

( a) Generall y h i gh er (6) Incl udi ng m o i st ure ( c)

. Mi neral Resources o f t h e U ni ted S tates 1 88 1
. . .

p 3 9 6 ( d) T ent h C e
"
nsus o f t h e U ni t e d S t a t es 1 8 8 0 X V p 7 2 ( e) E mm o n s G eo lo gy a nd M i ni ng
. . . . . ,

(3 ) Pri vat e co mmu ni

. .

Indust ry of Le advi ll e Co l o p 64 2 ( f) Tr A I M 8
. 1 89 0 9 1 x x
. x 1 03 4 . . . . .
-
. . .

cat i o n by C H Li vi ngsto ne (ll ) Pri vate co m muni cat i o n by M W Iles ( i ) Tr A I M E 1 9 0 4

mm
. . . . . . .
. . . .

2 89 .
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN ACE

Table 59 shows that the leadi ng consti t uents of coke ash are Si 02 and M 203 ; -

som e vari eti es contai n consi derable am o unts of Fe, o. In comp uti ng a c harge .
,

th e ash of the cok e has to be taken i nto acco unt .

Before cok e i s fed i nto the furnace all the fines have to be rem oved as they , ,

ch ok e the charge favor the formati on of accreti ons and not burni ng freely
, , , ,

ha ve to be carri ed out of the furnace by the slag Wi th more or l ess glazed .

p a rti cl es of fin e cok e t h e slag i s li k ely t o b e co m e d i rt y an d t o r eta i n p ar t i cl es

of m at te The separati on of fines i s done w

. i th a coke fork havi ng prongs -

i n apart whi l e rem

. ovi ng the coke fro mthe shed So meti mes a scoop i s used
,
.
,

an d the fines are scr eened out by d um pi ng the coke over a gri zzly whi ch di s
cha rge s th e coarse coke on th e feed floor and the fines i nto a bi n whenc e -

th ey are r em oved usually to be burned under a boiler occasi onally i n a gas

, ,

p rod u c e r or o t h er pl a c es wh er e t h ei r h ea t v a l u e c a n be u t i li z ed D w i gh t l
.

says t hat a reasonabl e am ount of fines such as usually accomp ani es a good ,

quali t y of coke does no harm and he condem ,

ns th ei r di scard by forki ng , .

1 2 5 Charcoal .
— As regards poro si t y charcoal i s the best fuel for a lead
.
,

f urnace as i t consi sts of a large number of small cells joi ned to each ot her by
,
2

poro us walls H ence bei ng readi ly oxi di zed i t i s a good reduci ng agent for
.
, ,

o xi di z e ores and does not requi re a hi gh blast whi ch i s an advantage I ts

, , .

grea t er porosi ty ca uses greater bulk t han coke ( 3 t h us m aki ng the charge

loo ser whi ch i s favorable for q ui ck sm

,
elti ng ; f ur t her i ts percentage of ash i s ,

low The great di sadvantage of charcoal i s that fewki nds can b ear any heavy
.

b urden ; i t breaks up and crumbles Fi ne charcoal i s not only worthl ess as a .

f uel but i t i s a bad co nductor of heat It makes unclean slags and also causes
,
.

loss i n m etal by i ncr easi ng t he am o unt of flue dust hence nobody uses charcoal -

al o ne unl e s s absol ut ely forc ed to do so Further the sm el ti ng zo ne tends to .

,

creep up and t hus i ncrease the loss of lead by volati li zati on .

N ut pi ne (p i fi on) charcoal i s th e best but i t has to be well b urned

-
Charcoal , .

fromli gh ter woods such as yellowand whi te pi ne quaki ng aspen and co tton , , ,

wood can not be used alone i n the furnace and even wi th coke only a small ,

percentage i s allowable; some metall urgi sts condemn i t enti rely M esqui te .

makes a good charcoal but i t i s obtai ned wi th di fli culty i n large pi eces Char ,
.

coa l fromhard woo ds such as mahogany ced ar and oak decrepi tates i n the , , , ,

furnace When charcoal i s exposed for any lengt h of ti me to the open ai r i t

.

breaks up and the am o unt of fines beco mes large On the o ther hand i ts quali ty .
,

i s sai d to be i m proved by stori ng thro ugh the oxygen t hat i t absorbs Lead ,
.

sm el ters do not li k e to have large am ounts of charcoal on hand It sho uld be .

s t ored wh er e i t i s not expo sed to the sun Charcoal has i n a fewi nstanc es .

been repl aced by an equi val ent i n reduci ng power of spli t woo d cut up i nto 1 2 i n -
.

lengt hs The wood keeps the charge open and the charcoal for med arri ves less
.

a
crush ed at the tuyére regi on than if i t had been charged as charcoal -
.

l
Tr A I . . . M . E
90 2 , .
,
1 m m365,
.

3
Thorner, 886, v1 , 71
S tahl und Ei s en, 1 .

m
H of an,
“
General M etallurgy, 1 9 1 8, p 2 08
”
. .

H of m Metallurgy of Cop per, 1 9 1 8, p 1 8 2

”
an, . .
302 ME TALLURG Y OF LE AD

Li ght wood charcoal contai ns about 2 p er cent of ash As this consi sts
-
. .

p r i n c i p ally of alk ali a n d a l kali ea r th c arbo na t es i t doe s n o t afl ect a cha rg e -

t o any appreci abl e extent One b ushel wei ghs about 1 4 lb The hei gh t of
. .

charge i t can bear vari es too m uch w i th the di fferent ki nds of charcoal to gi ve
a general fig ur e ; i n all cases i t i s l ess than w i th cok e .

1 2 6 Coke and Charcoal

.
—Fro mwh at has been sai d i t i s obvi ous that th e .

i deal fuel for the lead sm el ter m ust com bi ne the strengt h of coke and the porosi t y
of ch ar co al ; th us at least wi th a lowpressure blast a m ,
i xture of coke and -

charcoal wi ll p ut thro ugh more charges i n a gi ven ti me than ei ther alone Th e . .

coke bears up th e charge and prevents the charcoal fro mbei ng crushed Thi s .

burns qui ckly help s to i gni te the coke and havi ng hardl y any as h leaves h ol
, , , ,

low spaces for the blast to penetrate At present when furnaces are run wi th .
,

a pressur e of fro m2 to 3 lb to the sq uare i nch and oxi de ores forma sm all.

percentage of the charge charcoal i s never used The greater hei ght of furnace ,
.

and wi th i t of charge nec essi tated by the i ncreased volum e of ai r blown i nto t h e

furnace wo uld cause the charcoal to be broken; the fine charcoal would cause
,

the di sadvantages gi ven i n § 1 2 5 ; i t w ould burn near the top of the charge and
cause overfire 1

1 2 7 Cok e and Bi tum

.

.
—
i nous CoaL N ei ll succeeded i n 1 89 1 i n replaci ng part
’

of the coke by a non caki ng or only sli ghtly caki ng bi tum -

i no us coal usi ng sep a ,

rately l um p nut and p ea coal H e gi ves as results of hi s experi ments that

, , .
,

besi de the di rec t savi ng i n substi tuti ng the cheaper bi tum i no us coal for th e
coke j ackets slag and lead appeared ho tter the tuyeres bri ghter and the
, , , , ,

cr uci ble kept op en better The slag assays ran lower in values than wi th the .

us ual coke and charcoal m i xture and the separati on of slag and m atte w as ,

good On the feed floor the charges set tl ed more evenly as fewer zi nc acere
.
-

ti o ns were for m ed and the top w as cooler than usual

, Whi le the volume of .

sm o ke w as larger t her e w as no greater loss i n the flue dust on acco unt of the
,
-

charge bei ng cooler In hi s furnace 36 by 78 i n at the tuyeres and 1 2 ft .

, .
, .

fro m the tuyeres to the chargi ng—door he was usi ng coke and charcoal i n ,

the propor ti o n of 3 1 and w as able to have 2 7 p er cent of bi tum ,

i nous coal .

i n hi s f uel ch arge replaci ng an equi valent am , ount of coke H e expec t ed that .

wi th a hi gher furnace 50 p er cent of hi s fuel m i gh t be bi tum i nous coal . .

The exam ple of N ei ll i n usi ng mi xtures of coke and bi tum i no us coal i nstead ,

of coke or coke and charcoal has been followed by o thers and proved succ essf ul , .

Austi n gi ves a sum

” mary of 1 8 months experi ence i n the use of mi xed f uels ’

coke charcoal and bi tumi nous coal i n the blast f urnace ( havi ng a 1 2 ft
,
— -
.

worki ng hei gh t) of the Germ

,

ani a Lea d Works Salt Lake Ci ty U ta h Table , , .

60 contai ns the leadi ng data :

‘
Bretherton, Tr A I . . . M . E .
,
1 91 5, 730 .

3
09 . ci t .
, 1 89 1 , xx , 1 65 .

E ng . Mi n . J .
, 1 89 4 , war , 558 .
304 M E TALLURG Y OF LE AD

and co mbusti ble m

non -
i xtures of fine coal and ash es Dw i gh t p ubli shes som e .
l

exp eri m ents m ad e by Von der Rapp i n sub st i t ut i ng anthrac i te of goo se egg siz e -

for par t of the coke no charcoal bei ng used The furnace was 36 by 80 i n at ,
. .

t he tuy e r e level and 9 ft fromthere to the feed floor The resul t was tha t the
-
.
-
.

sm elti ng power of the f urnace w as red uced as the propor ti o n of anth raci te w as

i ncreased e g one th i rd wi th anthraci te as 60 p er cent of the f uel ; o therwi se th e

,
. .
,
-
.

f urnace remai ned i n good condi ti o n The top kep t cool and the cruci ble Open ; .

there w as a good red uc ti o n shown by a cl ean slag to p er c ent Pb) .

,

a m atte lowi n lead ( 8 p er c ent Pb 4 p er cent Cu) and a spei ss havi ng a coa rsely .
,
.
,

crystalli ne struc ture Fi nally less zi nc accreti ons were form ed t han wh en cok e .
,

alo ne w as used the ch arge co ntai ni ng p er c en t

,
Zn . .

1 2 9 Li qui d and Gaseous Fuel

. The use o f cr ude oil i nj ec ted at the tuyere .
-

level to replace part of the norm

, al am o unt of coke has been suggested but , ,

not t ri ed at least wi th lead blast f urnaces

,
In m at ti ng copper ores success .
,

has been clai m ed for the use of oil

’
.

Gaseo us f uel has been used i n a si ngle i nstance At the works of the Penn .

syl vani a Lead Co m pany Blak e introd uced natural gas wi th the blast by insert
’

i ng a gas pi pe thro ugh the tuyere pi pe The am o unt of natural gas was
m
- -
.

regulated by st0p cocks and the blast volum e i ncreased so as to supply su

- -

ci ent ai r for the co mb usti on of the gas Thi r ty p er cent of coke was succes s . .

fully saved i n thi s way By replaci ng 60 p er cent the top of the furnace . .
,

becam e too ho t That soli d f uel canno t be enti rely replaced by gaseo us i s
.

clear fro mthe reac ti ons goi ng on i n a blast furnace wh i ch requi re soli d carbo n .

For pec uni ary reasons i t i s i m probable that any arti fici al gaseo us fuel wi ll ever
be used i n the blast furnace .

1 3 0 W ei ght of Fuel
.
t — The wei gh t of fuel req ui red i n a lead blast furnace i s .

generally expressed i n terms of percentage of the to tal wei ght of the charge ( ore ,

flux and slag) Som e m

“
etallurgi sts prefer to m easure the i ndi vi dual cha rges
, .

of coke goi ng i nto the furnace i nstead of wei ghi ng them as the gr eat er or ,

sm all er am ount of water contained i n the coke i s li kely to gi ve wrong wei gh ts .

Th ey wei gh gi ven am o unts of dri ed coke i nto the chargi ng larri e mark th e ,

hei gh ts to whi ch these reach and are then gui ded by the mark i ngs i n feed ,

i ng the f urnace .

The si m ple statement that a furnace i s run wi th a defini te percentage of

coke i s not sufi ci ent to convey a clear i dea of how m uch heat i s bei ng used as ,

1
Tr A I . .
,
8.
9 1M,
xx ,
1 69. E . 1 .

Ha m i l ton, E ng M i n J , 1 9 1 1 , . . . xet , 2 44 .

Ki ddi e, op ci t 1 91 1 x cn , 4 34

W aters op ci t 1 9 1 2 x cm 8 77
.
. .
, ,

.
, . .
, , ,

Lang Mi n S c Press 1 9 1 3, CW 2 9 8
,
. .
, , .

Marq uard Canad Mi n J , 1 9 1 5 x xxvr 4 72

,
. . .
, , .

Tr A I M E 1 886 87 xv 66 1
. .
— . . .
, , ,
.

4
Austi n, Mi n S c Press, 1 90 7 xcrv 3 4 1 . .
, , .

Ralli Rev Un Mi n 1 9 1 1 xxxw 3 1 3 xxxv 1

,
. . .
, , , , , .

von Schli p p enbach Metall u E ra 1 9 1 5, x11 , 403 ,

. .
, .

‘ von Sch li pp enbach, loc . ci t.

 S M EL TI N G LE AD ORE S I N TH E BLAS T F UR NACE

th e percentage of ash i n di flerent ki nds of coke vari es greatly In recent y ears .

i t has becom e the cust omto add the perc entage of fixed c arbon to t he fig ur e

deno ti ng the percentage of cok e A f ur nace i s run wi th 1 3 p ercent coke whi ch

. .
,

wi th 86 p er cent F C corresponds to 1 1 p er cent C Mi sunderstandi ng

. . .
,
. .

o c casi o nally ari ses fro mded uc ti ng t he po unds of lead contai ned i n the ch arge

and referri ng the percentage of fuel onl y to the slag and m at t e m ateri al Of ten .

t he percentage of fuel used r efers to the wei gh t of the charge excl udi ng the slag
t hat i s ad ded for the reason that an addi ti on of slag because i t faci li tat es the
, ,

sm el ti ng does not w
,
i thi n ordi nary li m i ts call for extra fuel .

In general i t m ay be sai d t hat a f urnace req ui res fro m1 2 to 1 5 p er cent .

coke of the to tal wei gh t of ore pl us flux to run sati sfactoril y ; thi s figure wi th ,

co k e of 86 p er c ent C correspo nds to .

,
—
1 3 o p er cent C A charge wi th . . .

metalli c sulp hi des requi res less fuel than one that i s made up of oxi des A good .

rul e i s t o avoi d anyexcess of fuel and t o keep on t he ragged edge of r educti on

1
,

a s t hi s gi ves large to nnage long cam pai gns good furnace condi ti ons and good
, , ,

metallurgi cal work ; the slag wi ll assay p er ce n t P b an d b e fl ui d an d .

,

h ot ; the volum e of sm oke i ssui ng fro mthe throat wi ll be sm all and gray or ,

dark i n color ; and th e lead outp ut w i ll be good Over reduc ti o n i e usi ng t oo .

-

, . .
,

much fuel i s accompani ed by no end of di sturbances There i s danger of i ron

,
.

a nd copp er so ws ; of m aki ng m uch spei ss i n th e presence of arseni c ; the cr uci ble

c o ntent becom es sti cky ; the f urnac e ti gh t ens and speed i s lessened ; sl ags run

s lo w ly al though they are hot ; coke appears at the tap hole and whi te smok e and -

o verfire at the top ; sl ags co ntai n t oo li t tl e l ead vi z p er c ent an d s how ,

.
,
.
,

sp a rks of b urni ng cok e In under red uc ti on i e usi ng too li ttl e fuel the speed
.
-

,
. .
, ,

i s hi gh ; th e slags whi le flui d are cold and look heavy and run 1 p er c ent Pb
, , ,
.

a nd over ; a large vol um e of thi ck grayi sh whi te sm oke ari ses fromthe throat ;
,

a nd the yi el d i n lead i s bad The correc ti on i s m ade by addi ng say w

. i th a ,

sla g of 2 p er cent Pb 4 p er cent m . ore coke and then reduci ng thi s gradually
,
.
,

when the resul ts of the correcti on have been no ti ced If the f uel i s to be reduced .

when the furnace i s doi ng fai r work i t i s wi se to decrease by not more than 1 p er ,

ce nt at a ti m
. e In runni ng a newcharge i t i s advi sable to use a li ttle extra
.
,

fuel i n order t hat th e assays and physi cal appearances m ay for mcl ear gui d es

fo r m aki ng any nec essary ch anges .

The am o unt of C t heoreti cally requi red to smelt a charge can be calculated
fr o m t he ther m al b al anc e sh eet In prac ti ce the am ount of cok e t e
q u i r ed v ari es wi th i ts charac ter wi th th e f usi bi li t y of the charge wi t h th e
,
.
,

ti me ofe year w i th the al ti tude at whi ch the sm

,
el ti ng i s carr i ed on and the ,

re ssur of t he bl ast
p .

As regards the character of the fuel coke that i s ri ch i n ash i s not o nly an ,

i nf eri or fuel i n proporti o n to the sm all er am ount of C i t co ntai ns but a consi d ,

cra bl e q uanti t y of t hi s C i s co nsum ed to m el t t he ash and t he fluxes nec essary

t o s la g i t For thi s reason a sm

. all er am ount of charcoal than of cok e would
see mt o be r eq ui red The exac t opposi te however i s the case as the charcoal
.
, , ,

crum bles i s crushed i n i ts d esc ent i n the furnac e b urns m

,
or e to CO at the tu ,

Aust i n, loo . ci t.

20
306 ME TALLURGY OF L E AD

y eres than the denser coke and thus produces less heat whi ch has to be m adeup , ,

by addi ti onal f uel and i s oxi di zed m ore qui ckly by the C0, of the ascendi ng
,

gases than i s the coke .

The ri ch er an ore i s i n lead the less fuel w i ll be needed as the am ount of ,

gangue to be smelted i s correspondi ngly sm aller ; also the m ore fusi ble wi ll be
the r est of the charge An ore contai ni ng zi nc requi res m ore fuel t han one that
.

i s free fromi t ; a calcareous slag requi res m ore fuel than one that i s furruginous;
a coarse and Open charge req ui re s less f uel than one that r s fine and dense as
'

fine ore causes slow running .

In sum mer less fuel 13 generally requi red than i n wi nter not so much owi ng ,

to the hi gher t em perature whi ch m ay be co unted as balanc ed by the larger ,

percenta ge of m oi sture i n the ai r as to the more rapi d evaporati on of the water ,

contai ned i n ore flux and fuel The di fi erence m ay b e as m

,
uch as 5 p er ,
.

cent Furnaces run better at ni ght than duri ng the day as there i s less
.
,

moi sture i n the ai r .

The al ti t ude at whi ch an ore i s sm el t ed m akes a grea t difference i n the

am ount of fuel req ui red H ahn for i nstance i n 1 88 1 gave the figures of 1 4
l
.
, , ,

and 1 7 p er c ent i n Sal t Lake Ci t y ( 4000 ft above the l evel of the sea ) as agai nst
. .

2 2 and 2 4 p er cent i n Leadvi lle th e lower figure refers t o t he

.

sum mer the hi gher to the wi nter season A parti al explanati on of thi s fact
,
.

was gi ven by H eadden at a meeti ng of the Colorado Sci entifi c Soci ety i n that a ,

cubi c foot of ai r enteri ng the blast furnace under a cer tai n pressure wi ll expand
more at a hi gh elevati on where the ai r i s rarefied than at sea level and that , ,
-

consequentlym ore hea t wi ll be consum ed whi ch has to be m ade up by an extra

am ount Of fuel Thi s accounts however o nly for a sm . all p ar t of th e ex t ra , ,

hea t r eq ui r ed Palmer has shown that the di fi erence i n fuel consum

2
. pti o n
at hi gh i n co m pari so n wi th low elevati ons i s due to the fact that the veloci ty of
co mbusti o n i s di rectly proporti onal to the concentrati on of the O i n the ai r
ent eri ng thro ugh the t uye res As the temperat ure at the tuyeres i s propo r .

ti onal to the rate of com busti on of the C the low tem perature caused by t h e ,

slow b urni ng at a hi gh elevati o n has to be correc ted by addi ng m ore fuel to t h e

charge .

Lloyd records t hat i n m

a
atti ng sulphi de copper ore at an el evati on o f -

ft the sm el ti ng power w
. as lower and the pyri ti c efl ect sm aller th an

at sea level ; he al so sta tes as doe s Saci o that heat losse s by radi ati on ha ve
-
‘
, ,

to be avoi ded as m uch as possi ble The statem ents of bo t h gi ve addi ti onal ev i .

dence of t he slower rate of oxi dati on at a hi gh than at a low al ti t ude Si mi lar .

experi ence has been had i n roasti ng pyri te co ncent rates at di fferent elevati o n s .

The pressure of the bl as t has a great i nfl uence on the fuel consum pti o n
moni n the early ei ghti es theamount ofco k e
.

Wi th the pressure of 94 and 1 lb com .

, ,

needed at an elevati on of 5000 ft w as about 1 5 p er cent and at ft 1 8 . .

,
.

1
M i n Res U S , 1 882 p 399
E ng Mi n J , 1 906 m m 1 34
. . . . . .
,

. . .
.
, ,

—
Tr M et I ns t M i n I nd 1 909 1 0 1 1 1 . . . .
. .
, , ,

‘
S chool Mi n Quart , 1 9 1 3 xxxv, 34 4 ; M et. .
, . Che m E ng
. .
, 1 9 1 3, xx, 4 99 .
308 ME TALL URG Y OF LEAD

by o ther b ases w i ll be consi dered i n 51 36 and followi ng The freezi ng poi nt curve s .
-

Fi g 3 1 8 of the si ngul o si li cat e seri es 2 R0 Si 03 the sesq ui sili cate 4 RO 3 Si O,

.
,
-

,
.
,
-

,
.
,

and the bi si li cate RO Si Og show that th ese si li cates are eutecti c m

-

,
i xt ures ; the
.
,

exi stence of chem i cal co mpo unds has not been defini tely proved altho ugh there
i s at $ 0, FeO CaO 2 0 p er cent an i ndi cati on i n the si ngulo .

si li cate c urve of t he com po und whi ch contai ns

Si 02 FeO CaO p er cen t T h e m or e r ecent work of Z m i el ‘
.
,

deali ng wi th ferrous si li cates and of Konstanti nofi and Seli vanofl wi th ferro ,

calci c bi si li cates shows the general V—shaped formOf the freezi ng poi nt curve
2 - -

wi th the absence of a chemi cal compound whi l e that of Seli vanofl deali ng wi th ’
,

ferro cal ci c si ngul o si li cates poi nts to the exi stence of the chem
- -
i cal com po u n d
°
freezi ng at abo ut 1 2 50 C wi th an eutec ti c on ei ther .

si de t hat on th e FeO si de m
°
,
el ti ng at abo ut 1 1 50 C and that on the Cao si de
-
.
-

°
at about 1 2 1 0 C .

The form ati on tem peratures of the si ngulo si li cates of Fi g 31 8 are gi ven i n -
.

Table 6 1 T hey show t hat wi th the replacem

. ent of FeO by CaO t he for m ati on

tem perature of the ferro us si li cate of 1 2 70 C falls to 1 1 70 wi th the slag contai n ° °

.

i ng 1 6 p er cent CaO i t ri ses to 1 2 05 w

°
i th 30 p er cent Cao ; falls agai n wi th
.
,
.

TAB LE 61 —.FORuAn O N TE MP E RATU R E S or FE RR o -

CALcrc SI N G U LO -
S I LI CATE S

Che i cal m co mpo i ti on of

s slag

f ur ther replacement unti l i t reaches t he lowest poi nt at 1 1 3o wi th 36 per °

cent CaO ; and then ri ses steadi ly probably to the formati on tem
.
p erature of ,

2 CaO Si 02 w
°
hi ch li es at 2 080 C
. . .

The for mati on tem peratures of the sesq ui si li cates are gi ven i n Table 62 -
.

Th e ferro us sesq ui si li c ate has a lower form ati on tem

°
perature ( 1 1 2 0 C ) than
-
.

Rev . Met . E xtr , . 1 9 1 3, x , 61 1 .

Op . ci t .
,
1 9 1 3 ,
x , 60 7 .

Op . ci t .
, 1 91 5, 0
3 9 .
 SMEL TI NG LEAD ORE S I N TH E BLAS T F URNACE

the si ngulo si li cate

-
falls wi th the replac em
it a sol ent of FeO by CaO,
but reaches i ts mi ni mumwhen the sl ag contai ns 1 2 or perhaps 8 p er cent ,
. CaO .

T AB LE 62.
— F0R uAn ON TE MP E R ATU RES or FE RRo -
CALcrc SE SQ U 1 S1 L1 CATE S
-

m
Che i cal co mposi ti on of slag

Th e for mati o n temperat ures of the bi -

si li cates are gi ven i n Table 63 .

TAB LE 63 — FOR11 ATI O N TE M P E RATU RE S or FE RR o -

CALcrc Dr src
-
ATE s

m
Che i cal co mpo i ti
s on of Slag

mperature si li c ate for m C i s lower

°
T h e te whi ch the
at ferro us bi
s 1 1 10 -

,
.
,

th an t hat of the sesq ui si li cate 1 1 2 0 C ; i t i s also lower ed wi th r epl acem

°
-

, . ents

of FeO by CaO and reaches i ts lowest poi nt wi th a slag co ntai ni ng not more
,

than 8 p er c ent CaO . .

3 10 ME TALLURGY OF LEAD

The for mati on temperatur

of f erro calci c si l i cates are therefore the lower e
s -

the hi gher t he sil i cate d egree; a sl ag wi th a h i gh si l i cati o n reaches i ts m

-
i ni m um
formati on temperatures wi th l ess CaO than one i n whi ch i t i s low .

The m ai n slag for the lead blast furnace i s t he si ngul os i li cate; i n m ost cases
however i t i s m
,

ad e sli gh tly m
, ore si li ci o us than called for by the formula .

Calc ulati on of the for m ul a fro mthe ch em i cal analysi s often shows that a
‘

slag i s m ade up of ferro us si ngulo sfli cate ( 2 FeO Si Og) and calc i c bi si li ca te -
.
-

Of the m any po ssi ble m i xtures of ferro us and calci c si ngulo si li -

cates cer tai n defini te proporti o ns of SlOz FeO and CaO have been fo und to
, , , ,

work sati sfac tori ly i n the lead blast f urnace; th ey have become representati ve
for the work Accordi ng to Ei lers such a Typi cal Lead Slag should not contai n
.
'

over 5p er cen t P b or oz A gp er ton prov . i d ed th e le ad b ulli o n do e s n o t .

,

run hi gher than 300 oz p er ton ; nor have a densi ty ov er nor per m
. i t ei th er
accreti ons i n the hearth s ( th us k eepi ng red h ot the lead i n the cruci bl e) or any -

creepi ng up of heat The lead and si lver contents of slags m

,

. ade at present are -

hi gher as the ores treated are not so pure as those sm

, el ted i n the early ei gh ti e s .

Table 64 gi ves such typ i cal slags The com posi ti ons of the slags have been
“
.

calculated to to ta l 90 leavi ng 1 0 p er cent for o ther com ponents such as 303

, .
, ,

Zuo alk ali etc

,
In sm el ti ng ores that contai n fewof these o th er co m
, . ponents
the sumof SlOg FeO and CaO w i ll often to tal 95 or 96 per cent ; if however
, , .
, ,

thi s i s not the case the sumOf the three m ai n consti tuents m
, ay be only 85 or 86 ,

and even l ess as shown i n § 1 4 5 i n connec ti on w i th zi nc and as found in sm el ti ng

ores fromCri pple Creek Colo runni ng hi gh i n

, ,

.
, ,

TABLE 64 — T YPE S or . LE AD St Acs

Eilers Q ter slag

uar

Three quarters slag -

. .

One to one - -

Si li ci ous quart er slag .

Sili cious half slag

H alf slag
Si li ci ous half slag
Three quarters -

The spec i al na m
gi ven i n column 3 Of Table 64 are based upon the rati os of
es

FeO and CaO ; th us slag of type C i s call ed a quar ter slag on account of FeO
CaO approxi m ately Thi s no menclature ori g i nated i n the i dea of slags .

bei ng chemi cal co m po unds; i t has lost i ts supposed value but is gi ven as i t ,

i s sti ll much i n vogue .

1
Grap hi cal s entati on
rep re by Li ddell, E ng . Mi n . J .
, 1 9 1 4 , xcvn , 31 8 .

D emi ng J ,
I nd.E ng C he , 1 9 1
. 6 , V1 11 ,
2 69 . m . .

Table for such slags , see H of an, H O , m . . M etallurgy of COp p er, M cGra wHi ll -
Book
Co .
, N ewYork , 1 9 1 8, p . 200 .

3
Eng . Mi n J . .
,
1 88 1 , xxx x, 2 46 .
312 ME TALLURGY OF LEA D

An i nteresti ng instance of a large di fference betw een the tw o te peratures i s m

Shown by exp eri enc e of Carp enter i n mat ti ng Cri ppl e Creek go ld ore at Florence,
‘

Colo . l rge amount of alkali i n the phonoli te rock caused the

The pr esence of a a

formati on of glassy slag at a temperature lyi ng very much belowthat neces sary
for free flowi ng and the furnace froze On pulli ng down the fro nt the furnace
-

,
.
,

was fo und to be filled more or less wi th glass An addi ti on of Mgo bea ri ng .

-

rock to th e charge Of the next run correc ted the evi l .

A slag o ugh t to be sufli ci ently fl ui d to flow freely and to allo wa perfect

separati o n of l ead i n the furnace and of m at te i n the fore hea r th A correc tly
w
-
.

co m posed slag hi ch wo uld oth erwi se be fl ui d beco mes vi sci d i f the wea ther
, , ,

changes to wet or cold ; i n such cases more fuel i s req ui red I t i s difli cul t even .
,

for the prac ti ced eye to say always whether the vi sci di ty comes fromlack of ,

f usi bi li ty or froma sli gh t i nsufi ci ency i n fuel As a r ule si ngulo si li cate slags .
,
-

contai ni ng ear thy and metalli c bases soli di fy q ui ckly wi thout first becom i ng
pasty W hen the tap hole has been clo sed the slag if good will drop slowly
.
-

, , ,

i nto the p ot drawi ng a sm all thread as i t l eaves the spo ut ; a slag w

,
i th an excess
of b ase wi ll fall Ofl qui ckly i n li ttle ro und drops Most slags have certai n .

charac teri sti cs i n thei r manner of runni ng whi ch have to be studi ed by O bserva ,

ti o n . I n clo se co nnec ti o n wi th the runni ng Of the slag fro mthe furnace i s the
manner of i ts ri si ng i n the slag pot and the app earance of the surface when i t -

has j ust soli difi ed and i s sti ll red Many slags show very charac teri sti c .

surf aces th e slag type E T able 64 wi th Si 02 30 Fe0 40 CaO 2 0 p e

. rcen t , , , , .

show s a sli gh t thread w hen dropp i ng fro mthe spout When ri si ng i n the p o t .
,

more or less concentri c ri ngs are seen and radi al li nes (usually four) when the ,

p o t i s a bo u t f u ll .

The m el ti ng po i nts of lead bl ast f ur nace slags li e near er

-
than C -
.

Schertel gi ves’
C Guyard assum “ es I les finds
5
Goetz .
,

( q u o ted by I le s) fi nd s a r an g e fro m t o L an d i s
‘
g i ves C le v e n
d w ances the tem of l g flow i g fro m f c
'

g e r
"
fi n s i n t o i ns t p era t ttr es s a s n urn a es t o

be and C .

Th ehea ts of formati on fromthe co nsti tuent oxi des per kil ogramof sili cat e 8

Show val ues rangi ng from 1 33 to 1 93 Cal Addi ti o nal data regardi ng .

si ng ulo and bi sili cates of i ro n and m anganese have b een found by -

Wolgodi ne °
.

The speci fic hea t betw een zero deg C and the m el ti ng poi nt t i s o 2 0 1 85+ . .
-

, , .

0 0000302 t and that at the m

. el ti ng po i nt
, + 0 000604t -
. .

Tr A I . . .M . E .
, 1 900 , xxx , 1 30 .

Austi n, Mi n . S c Press, . 1 0
9 ,7 x crv,
2 5 2 .

Frei berg J ahrb , . . 1 880, p 4 5 . .

Loc ci t , p 744. . . .

S chool Mi n Quart 1 89 5 9 6, xvn, 2 0

— . .

“
Ri chards, J W , M etallurgi cal Calculati ons
’
. . . McGraw
500 .

7
Met Chem E ng , 1 9 1 3 x x 44 8
. . .
, ,
.

‘ H of man W en Tr A I M E 1 9 1 0,
-
. . . . . .
, 5 1 1 .

Rev Met E xtr 1 9 1 4 xx 39 5

. .
, .
, ,
. .
 S M ELTI N G LE AD ORE S I N TH E BLAS T F URN ACE

”
The to tal heat of fusi on i s gi ven by Landi s as 302 Cal and by ‘
. Austi n
as 300 Cal p er kg L a n .di s g i v e s th e h ea t co nt.e n t sol i d a t C ( t h e , .

mel ti ng poi nt) as 2 62 Cal hence the latent hea t of fusi on i s 40 Cal
-
.
,
.

1 33 Physi cal Properti es — Crystalli zati on —

Well co m p o s e d sl
.a g s ha v e a .
-

deci ded tendency to crystalli ze The center of a co ne of slag i s generally more . .

cry stalli ne than any o ther p ar t because the cooli ng has been slower The slag .
,

$ 0: 30 FeO 40 CaO 2 0 p er cent fro ma bi g p ot as well as froma ladle

,
“ ,
.

sam p l e w i ll sh ow cry st a ls i n th e c en tr a l p a r t A n ex c ess of F eO te n d s t o w a r d .

th e for m ati o n Of large cry stals whereas an excess of CaO favors a m ore granular
,

st ruc t ur e The cry stalli ne charac ter Of the norm

. al Slag extends to the surfac e;

i f i t stop s shor t of th e edge and thi s has a ,

r eddi sh ti nge there i s an excess of SlOg; if ,

the cavi ti es i n the central p ar t sh ow no

crystal s but are smoo th and hard looki ng ,

t h ere i s an excess of FeO i n regar d to Si 02 ;

if t he top of a bi g p ot has a sm oo th surface ,

th e slag contai ns an excess of CaO over th e

no rm al .Slags that crystalli ze usually be
come am orpho us ( glassy) if chi lled sud
denly and cryp to cry stall i ne if not gi ven
,
-

sufli ci ent ti m e to develop cry stal s A sm all .

percentage of zi nc oxi de i n the Slag i nter

feres grea tly wi th the crystallizati on Iles ‘
.

t ho ugh t at one ti m e that the formi n whi ch

a Sla g cry stal lized stood i n som e r elati o n to

t he percentage of li m e i t co nta i ned He .

sai d Fi g 3 1 9 t hat slags wi th fro m3 to 5

9
Fm
.
, ,
O f lead SIags
c cry l k w h
'

f C O l i li i 8
’

t t
'

p er e n O a . s a z e e a ; t
t o 1 2 p er cent l i k e a wi th 1 5 to 1 8 p er cent li ke 6 w
'
.
, i th 1 9 to 2 2 p er c ent .
,
.

li k e 6 wi th 2 3 to 2 5 p er cent li k e d w i th 2 5 to 2 7 p er cent lik e e w

,
. i th 30 , .
,

T he form and h represent crystals form

’
t o 3 5 p er cent li ke g . s f f . ed i n , ,

a t tem pti ng to slag very si li ci o us ores wi th li me alone But the p ercentage .

o f CaO can no t be the o nly cause for th e di fferent form s of cry stall i z ati o n ,

a s Rah t ob tai ned froma si ngle p ot of slag three difi erent form s of large well
Ii
,

develo ped crystal s of app roxi m ately t h e sam e co m po si ti o n gi ven i n Table 66 ,

.

I t i s to be no ted that th e sam e slag wi ll m el t at a lower tem peratur e when

glassy than when cryp to— crystal li ne Thi s i s due to the di fferenti ati o n that .

occ urs i n cool i ng cry stal s form i ng on the one hand and gro und m
,
ass on the ,

o t h er bo t h of w
,
hi ch have di flerent comp o si ti o ns and di fi erent physi cal prop er
t i es. Thi s i s i m p or tan t i n t a k i n g a s a m pl e for ch e m i ca l a nal y s i s .

Lac . ci t .

Min . S c Press,
. 1 0
9 ,8 XCVI , 560 .

Austi n, loc . ci t .

Mi n . Res U S . . .
,
1 883 —8
4, p .
44 0 .

Proc Colo S c S oc ,
. . . .
—
1 89 1 03 , W , 304 , and pri vat e co mmuni cati on, Ap ril , 1 89 7 .
3 14 ME TALLURG Y OF LE AD

TABLE 66 — AN ALYS E S
. or SLAG S or SAME CouPo srrron B UT DnrrE RE N T CR YSTAL Fon s

—
Tenaci ty There i s so me vari ety i n the tenaci ty of slags . Si li ci o us slags are

generally to ugher than those i n whi ch the base prevai ls The more crystal li ne .

a slag the m
, ore bri ttle A p ot of slag m ay show bri t tleness i n one part and
.

to ugh ness i n ano ther .

S pecific Gravity The speci fic gravi ty of a slag i s an i m

— portant fac tor in i ts
separati on froml ead and p ar ti c ula rly fro mm atte whi ch h as a sp ecifi c gravi ty ,

of abo ut 5 Iles gi ves as extreme figures and as a com mon range

‘
.
, ,

for good slags and The average Speci fic gravi ty of 1 00 determ

, i nati ons
Of good slag s gave hi m and i s accep ted as the hi ghest specific gravi ty
a good slag o ugh t to hav e .

—
Di aphanei ty Slags do not possess to any extent the property Of trans
.

mi tti ng li ght Si ngle crystals i n excepti onal cases are transparent ; sometima
.

t hey are transl uc ent but generall y Opaq ue , .

Colon Lead slags are usually black from t hei r hi gh percentage Of i ron
-
.

Thi n pi eces som eti m es appear greeni sh black ; a large am ount of i ron wi ll gi ve
a browni sh hue Li m e produces a bl ui sh or grayi sh to ne
. .

—
Len ten The l uster of slag vari es I t i s occasi onally m etalli c but generally .
,

vi treo us to r esi no us Very Of ten slags are dull

. .

Magneti sm Some lead slags S howmagneti c proper ti es caused by the p res

— .

enc e O f Pe3or or m ag neti c i ro n sulphi de FegSg T he Fe.o. m ay be due t o , .

im perfec t reduc ti on of F8 303 or to the use of magneti te as a flux i t may be , ,

formed by the reac ti on: In all p robabili ty i ts

formati on i s governed by the Si Og content of the slag a hi gh percentage -

bei ng unfavorabl e to i ts formati on ‘

N ei ll i n exam
‘
i ning for thei r m agne ti c .
,

proper ti es a large number of lead slags runni ng from2 8 to 34 p er cent FeO .

,

fo und that th ey were not attrac ted by the magnet ; but wi th hi gher percentages ,

‘
Loc ci t
. .

“ ”
Berthi er, Trai té des Essai s par la voi e seche, Tho i ne, Pari s, m 1 834 , 1 , 8
3 5 .

‘ Wheeler K rej ci
, Tr A I
-
M E , 1 9 1 3, X LVI , 56 2
. . . . . .

4 Tr A I
. M E 1 89 1 , xx, 586
. . . . .
316 ME TALLURGY OF L E AD

s o metimes si deri te FeC03 The use of magneti te Fe304 as a fl ux has gi ven ,

.
, ,

ri se to some di sc ussi on The fac t i s that magneti te i s di fli cult of red uc ti on;

‘
.

hence a f urnace usi ng i t as flux must have stro ng red uci ng condi ti ons As these .

are not easy to co ntrol th ere m ay be ov er and und er reduc t i o n I t has been ,
-
.

Shown i n § 1 33 that a hi gh Si O, slag i s unfavorable to the form ati o n Of Fego. ; -

hence w i th m ag neti te as a flux a low SlOz slag has to be avoi ded -

.

1 36 M anganese .
— The fluxi ng p rop er ty of M no i s si m i lar to that of Fco ,

and M no i s usually figured i n a charge as eq ui val ent to FeO the m olec ular ,

wei ghts bei ng 55 and 56 H ofman ’

.

has Shown Fi g 3 2 1 tha t the ,

.
,

formati on tem perature of a ferro

calci c slag i s rai sed by sub sti t ut
i ng MnO for FeO I t i s known .

from prac ti cal experi ence that

M nO FeO slags have a greater -

fl ui di ty than FeO slags .

T he seri es Mno Si os has been -

n o E p ru d by n o o o
studi ed by Doeri nkel and the
’

F1 0 3 2 — E fl ect of MnO upon form ati o n tem

'

. 1 .
p er bi sili c ate seri es of MnO and C3 0 -

ature of a ferro calci c sili cat e

by Gmsberg
-
.
4 .

T he com monest manganese mineral i s pyrolusi te MnOz I ts oxi di z i ng ,

.

po wer has been Sai d to be the cause that certai n slags ri ch in MnO have so
hi gh a tenor i n Ag Thi s seem s to be contradi c ted by the fac t that slags .

ri ch i n M no T able 67 have been m

‘

,
“
ade by Ch urch th at ran low i n Ag and ,

Pb t he lead b ulli on averaging 3 1 4 oz to the ton

, . .

The oxi di zi ng power of oxi des of m anganese on blende i n the reverberatory

f urnace when sulp hi de copper ores are smel ted i s menti oned by Pearce
,
‘
, ,

T AB LE 6 7 — AN ALY S E S . or SLAcs c n 1N M AN GAN E S E AN D POO R 1N Srrvnn

who ob tai ned a slag of Si 02 4 8 p er cent Mno 30 p er cent and ZnO 1 2 5 per .
, .
,
.

cent so me Mn ( 3 p er cent ) also enteri ng the matte ( 50 to 60 per cent

.
,
. .

Cu) as M nS The oxi di z i ng power for blende has been no ti ced i n blast
.

Colquhoun, Mi n . S c Press,
. 1 90 5, x c, 69 .

Nei ll, loc ci t , 69 , 1 33 . . .

Tr A I M E , 1 899 ,
. . . . . xx r
x, 704 .

Metall urgi e , 1 9 1 0, m
v ,
20 1 .

‘
Zt . anorg . Che m .
, 1 90 8, e , 34 6 .

Tr A I M E —
1 886 8 7, 6 1 2 ; S chool Mi n 88 —8 v
. . . . .
, xv, .
Quart , 1 .
3 5, , 2
3 .2
0 Tr . A I . . M . E .
, 1 88 2 -
83, 11 1 , 59 .
 S MEL TI NG L EAD OR ES I N TH E BLAS T F UR NACE

ro asti ng i n a D wi gh t Lloyd si nter ing m achi ne Iles beli eves that i n the blast -
.

furnace th e amo unt of matte and spei ss formed di mi ni shes wi th the i ncrease
of M n i n the charge H arbordt gi ves i t as hi s experi ence that the percentage
‘
.

of matte formed i s not afl ected unless the Mn i s present i n considerable

q uanti ti es Furman says that wi th from 1 0 to 1 2 p er cent M nog i n the
’
. .

ch arge the oxi di zi ng power i s no ti ceable Ano ther peculi ari ty of MnO i s that .

i t red uc es th e di ssolvi ng pow er Of a slag for ZnO Mgo B aS and M et As ; , , , .

so m e m etall urgi sts hold th at i t i ncreases the sol ubi li ty of Met S

1 37 Li m
. .

e — Th e m
. anner i n whi ch CaO repl ac es FeO i n a Slag can be

ex p r essed by 4 FeO 2 Si Oz 2 PbS 2 CaO + 2 C 2 Pb 2 FeS ( 2 CaO Si Oz+ . .

2 F!O . SI02) 2 CO .

The earl i est record of maki ng a hi gh

l g i n a lead blast furnace i s that -
CaO sa

by Gri mer who states that at La Pi se the furnaces were run on the slag Si 09 30
’ '

, ,

FeO 4 0 CaO 2 0 p er cent

,
Thi s slag w as bro ugh t i nto pro m i nence i n the Uni ted .

S tates by Anton E i ler s and has b eco m e a stand by ( type E Tabl e The ,
-

first m an t o m ak e i ndependently a hi gh Cao slag w as August Rah t w ho i n -

1 88 1
4
created the typi cal slag G Table 64 wi th Si os 35 Fe0 2 7 Cao 2 8 p er , , , , ,

cent .

The efi ects that Cao has upon the form ati on tem peratures Of FeO si li cates
'

have been shown i n Fi g 3 1 8 The low formati on temperatures of the general . .

run of calca reous slags m ak es th emm ore flui d at the prevai li ng blast f urnace
t em p era t ur e s t h an th e f erro us sl ags of th e sa m e si li c at e d e gr e e ; h en c e C a O i s

sai d t o i ncr ease the fl ui di ty of a slag .

S c hnei der fo und that wi th sl ags contai ni ng m

“ uch CaO less m at te i s for m ed

t han wh en t hey are ri ch i n FeO and also that th e m at te i s lower i n Pb and ,

hi gher i n Ag H e explai ns i t by sayi ng that CaS i s formed and th en

.

di ssolved by the Slag I ts pr esenc e i n Leadvi ll e slags has b een proved .

by Guyard i n cOpp er slags by Bai kofl and i n laborato r

‘
,
7
y exp eri ments ,

by Schii tz 8
The sol ubi li ty of Met S i de i n Slag i s sm
. all
’
as sl ag a t th e .
-

utm ost contai ns from 2 5 to 3 p er cent S The di ssolvi ng p ower i ncr eases . . .

wi th the temperature and basi ci ty and vari es w i th the charac ter of th e ,

bases Jup tner gi ves the S content of a ferro calci c bi si li cate as

.
‘0
p e r - - -

cent and of a si ngulo si li cate as

.
,
and p er c en t ; h e fi n ds th a t -
.

an i ncrease i n th e p erc entages of CaO FeO MnO and ZnO has a tendency , , ,

to rai se the S content The use of CaO i n slags i s li m

-
i ted by forei gn m atter .

i n the ore and especi all y by the presence Of Zn

,
In a general w ay i t m ay be .

Pri vate co mmuni cati on July , , 1 89 1 .

S choolM i n Quart 1 89 9 3 .
, 2 —
, x l v, 31 5 .

Ann M i n 1 86 8 x m 36 7
m 734
. . .
, , ,

Eilers Tr A I M E 1 9 1 5,
. . . . .
, , , .

—
Tr A I M E 1 882 83 x 1 8
. . . . .
, , , 5 .

‘
Loc . ci t .
, p .
73 .

7
H of man M ostowi tch -

,
Tr A I . . . M . E .
,
1 9 1 0, x u , 783 .

Metallurgi e , 1 90 7, Iv, 69 7 .

H of man ,
“ n
Ge eral Metallurgy ,
1 9 1 8, p .
4 65 .

J . I ron and S teel I nst , . 1 90 2 , 1 , 32 7 .

3 18 ME TALL URC Y OF LE AD

Sai d wi th zi ncky ores the less CaO and the more FeO a slag contai ns the
that
better wi ll the furnace work It does not seemadvi sable to go beyond 1 6 p er .

cent of CaO i n a slag if from9 to 1 2 p er cent of ZnO i s present i n the charge

. . .

For exam ple the quarter slag C Table 64 wi ll readi ly hold 1 0 p er cent ZnO ;
, , , , .

the half slag E p er c en

, t ; th e t hr
,
ee q u ar ters s la g F 6 .
5p er c e nt ; th e o ne t o -

, ,
. .
-

one la g G h a r dl y a n a t all If t h C a O —c o n t n t e x c d 8 e r c n t ( a ccord

s , y,
e e ee s .2 p e .

i ng to so m e m etall urgi sts 2 4 p er ZnO wi ll not enter the slag but for m
,
s ,

i n part a m ush whi ch i ncrusts the furnace and i s i n part volati li zed A hi gh , .

Si Og content appears to assi st the Zuo to enter the m

-
at te; a low the sl ag ,
.

The use of CaO low ers the Sp ecifi c gravi ty of the sl ag and therefore fa vors

the separati on of m a tte and slag .

Li m est one C3 C03 i s the rock whi ch i s used to furni sh the nec essary CaO
, ,
.

Under atm osph eri c pressure i t i s di ssoci ated i nto CaO and C03 at 9 1 0 C ‘ °
Th e .

purer th e m i neral especi ally the lower the SIG: and N 303 the greater wi ll be
, ,

the CaO content avai lable as flux

-
.

Burnt li m e i s rarely if ever used i n the blast f urnac e ,

Brethert on states
,
’
.

that at the Am eri can Sm el ter Leadvi ll e Colo h e used for 8 years b urnt
, ,
.
,

li me i nstead of li m estone w i th the resul t not only that the furnaces p ut thro ugh
,

more ore wi th the same labor and fuel than wi th li mestone but that cleaner ,

slags were prod uced So m e of the lea di ng Colorado l ead sm

. el ters experi m ented

system ati call y for m onths wi th burnt li me and findi ng no metall urgi cal or ,

econom i c benefit returned to the use of li m , est one .

Burnt li m e w as used m any years ago i n the i ron blast furnace and i s sti ll ,

so used i n so m e i nstanc es i n E ngland .

The supposed advantages were that m ore ore co uld be p ut through p er uni t
of f uel i n a gi ven ti me (as 56 CaO charged are equi valent to 1 00 CaC03) that
the h eat cons um ed by dri vi ng O fi the 44 CO, i n the blast f urnace w as sa ved ;
'

and that the pa rti al red ucti on Of the 44 C0, by means of C di d not occ ur .

Gri i ner calc ulated a savi ng of 1 0 per c ent of fuel by the use Of b urnt li m
8
e; .

Bell m‘
ade i t o nl y p er c e n t Th e r eas o n why b u rn t l i m e i.n th e i ro n b la s t
furnace has been gi ven up i s that i t absorbs C03 and H gO vapor fro m -

the f ur nace gases a heat up to redness assi sti ng th e ab sorp ti on Of C03

,
Ii
,

and C8 03 par ti ng even l ess readi ly wi th th e co m bi ned H zO than wi th C03 .

T ho ugh the absorp ti on generates the sam e am o unt of heat that the expulsi on
consumes i t occurs i n th e up p er parts of the furnace warmi ng the gases
, ,

t hat are passi ng out ; m eanwhi l e th e lower par t i s b ei ng cooled by the

expulsi o n and thi s has to be m

,
ad e up by an ext ra am o unt Of f uel If li me i s .

to be used the li m e m,
ust be burned i n large pi eces and the b urni ng m ust be
very co m plete and even carri ed to Si nteri ng i f possi ble wi th i mpure ,

li mestone) , so as to di m i ni sh the abso rp ti on of CO , and H 30 The appa .

Zavri efi , Co pt rend , 1 90 7, c m . mv r , 4 28 .

E ng M i n J , 1 89 3, LV, 1 96
. . . .

Ann . Mi n , 8 7 1 , xx, 3 2 5 ; and Di ngler s Polytech J

. 1
’
. .
, 1 87 2 , corv, 309 .

“Chem m
i cal Pheno ena of Iron S elti ng, ondon, m L 8 7 2 , p 1 38 1 . .

“
Bell , Manufacture of I ron and Steel,
"
L o ndon, 1 884 , p 60 . .
320 ME TALLURGY OF LE A D

to 36 p er cent Si og, the A130; ac ts nei th er as a base nor as an aci d , but i s si ply
. m
di ssolved i n the slag ac ti ng as a stiffeni ng i ngredi ent A si i lar opini on is held, . m
wi tho ut li mi ti ng the Si Og co ntent by Dwi gh t and Mathew son for lead and
-

,
‘

copper blast furnaces ; Boggs fo und that in a ferrugi no us COp p er blast furnace
1

sl ag he co uld neglec t A130; i n hi s charge calc ul ati o ns as lo ng as i ts am

,
ount

if ‘
A M
Provost!» of 02 0 Rep laced

Fro 3 2 2
. .
— Efi cc ts of Mgo , B2 0, and ZnO upon formati on mperature of
te a farmcalci c
-

di d not c d 1 0 p er cent Mathesi us and Johnson state fro mthei r experi

ex ee .
’ ‘

enc e w i th i ro n blast f urnac es t hat A130, i s chemi cally i ndi fi erent i n the forma

ti on of Slag ; thi s does not agree w i th the research es of Ranki n and Wri ght of
the ternary systemCaO AlgOg Si Og
— — ‘
.

Tr A I
. . . M . E .
, 1 91 6, Lvr, 6 2 7, 94 2 .

’
Loc . ci t .

‘
S tahl u Ei sen, . 1 908 , xxvnr, 1 1 2 1 .

Tr A I M E 1 9 1 2 , x u y , 1 2 3 ; 1 9 1 6, W I , 94 1
m
. . . .
,
. .

1
Am J S ci ence,
. . 1 9 1 5, c r
xxrx. 1 .
 S MELTI NG LE AD ORE S I N TH E BLAS T F URNACE

H ah n thi nk s that A LO. always acts as a base, and says that an i ncrease
‘

of A10 . req ui res also an i ncrease of Si 03, or , what wo uld be the sa e, a m

decrease i n the bases Schnei der fo und that as a general rul e an i ncrease of
.
’

up . calle d for an i nc rease i n the propor ti on of CaO Thi s ay ean a . m m

decr ease i n Slog, the A130; a cti ng as an aci d .

H owe, 3
su mmi ngggests that up the state ments of H ahn and Schnei der , su

the pa r t p la yed by A130: m ay depend upo n the propor ti on of the o ther tw o

fluxes CaO and FeO and that i n calcareo us si ng ulo si li cates low i n FeO A130.
, ,
-

, ,

may act as an aci d and i n ferrugi nous slags low in CaO as a base The i dea , , , .

seem s to be co nfirm ed by the experi ence of Peter s i n sm

‘
el ti ng Mount Li ncoln
“
ores i n Colorado H enri ch b eli eves that A130; al w
‘
ays ac ts as an aci d ; he .

31 it it 96 96
“
Peep ers! of l lu Const i t uents Rep laced

Fro 3 2 3 — Efl ect. . of ALO . upon formati on te mp erature of a ferro calci c

-
sili cate .

p rop o ses t wo typ e s O f si li ca t e al u m i n ate s : m o n o sili ca te a l um i n a t e ( 2 A 1203

-
.

3 S lo g) ( 8 M eta l Ox i de + 4 E a r t h O xi d e); 1 1 B i s i l i ca te a l u mi .
- -

nate ( 2 Al303 QSI02) 2 ( 8 M etal + 4 E ar th Oxi de) ; O m d Ob

.
=2 : 1 -
.

Th e experi m ental evi dence of H of m an gi ven i n Fi g 3 2 3 shows that replac e

’
.
,

ment of SlO, by N 203 rai ses the formati on temp erature of

,

C of the .

basal sla g ( Slog FeO CaO 32 per and that replacem ent

of CaO lowers i t to a cer ta i n ex tent If the tw o rep lac em ents are co m bi ned .
,

i t ough t t o be po ssi ble to m ai ntai n the o ri gi nal for m ati on tem perat ure Of 50 C °
.

Practi cal experi ence i n sm el ti ng lead bear i ng bri ck b ats and o th er al um i no us -

materi al of a refinery has corroborated thi s If e g wi th a slag Si 02 36 .

,
. .
, , ,

Fe0 33 C30 1 5 p er cent an al um

, i no us m ateri al i s to be sm el ted par ts Of bo t h .
, ,

Mi n Res . . U S . .
, 1 882 , p 3 2 8 . .

1
Tr A I . . . M E . .
—
1 88 2 83, x 1, 57 .
,

Eng . Mi n J . .
,
1 883, xxxvr, 306 .

I bid p 32 2
.
,
. .

Tr . A I M E . . . .88 2 83, 11, 31 0

, 1 -
.

E ng . Mi n J . .
, 1 886, xu r, 40, 75, 1 2 8 ; B all A I . . . M
E , N ove ber, 1 9 1 6, p
. . m . 2 08 1 ; February,
1 91
7, p . 2 08 1 ; June , 1 91 7, p 9 89 ; Sep te
. mbe r, 1 9 1 7, p 1 4 73 (J ohnson)
. .

7
Tr A I . . . M E . .
,
1 89 9 , xxrx, 71 0 .

21
322 ME TALL URC Y OF LE AD

Si 02 and best replaced by N 203 and the FeO left i ntac t The slag
CaO are , .

produced wo uld have th e followi ng compo si ti on: SIC: 30 FeO 33 CaO , ,

( e q u i v ale n t t o 3 A l a) A 130 ; 6 ( re p la ci ng 6 S i o s ) T h e pr e se n c,e of A 10 ; h as .

a tendency to m ak e the sl ags glassy If i t i s not found necessary to reduce t he .

Slog co ntent of the slag the A130, i s figur ed into a charge as rep laci ng Ca O
-

, ,

t hat i s 1 03A1203 = 6C aO or ro u g hl y 2 Al203 replace 1 Ca0

, 5 ,
.

1 40 Fluorspar .
— Thi s i s of less i m por tance at present than used to be th e
.

case I t is known that w

. i th BaSO . and CaSO . i t form s readi ly f usi ble m i x tures ,

that i t assi sts i n th e fl uxi ng ZnS and ZnO but t he m anner of i ts ac ti o n has not ,

y et b ee n e x p l ai ned T h e o n l y r e s e a rch a l o n g t hi s l
. i n e i s t h a t O f K a ra n d é ef‘

who fo und that CaFg mel ting at C form ed wi th CaSi O a m ,

el ti ng at .
, ,

C an eutec ti c w
°
.
, i th p e r c e nt C a F g fr eez i ng at 1 1 30 C . .

I ts chem i cal efi ect i n volati li z i ng Si as Si F. need not be tak en i nto consi dera
'

ti o n Fo eh r clai m s th at th e presence of fro m1 to 5 p er c ent (3a i n the roa st

2
. .

i ng of ores i n the reverberatory furnace saves f uel and that addi ng i t to the ,

charge i n r efini ng lead prevents sho ts of lead fro mbei ng retai ned by th e li th
arge ; but gi v es no proofs .

If fluorsp ar i s used i n a sm el ti ng ch arge one has to rem em ber that i ts Ca is ,

not avai labl e as a b ase for fluxi ng Si 02 but rem ai ns i n co m bi nati on wi th F ,

Ores fro m nor thw estern Mexi co of ten co ntai n Ca ; the p erc entage of F has

to be k nown before a correc t calc ulati on of th e am ount of CaO needed ca n

be carri ed out .

141 —
S lag There are four reasons for th e use of S lag i n blast f urnace
. .

ch arg es : ( 1 ) I t may contai n too much Pb or Ag to be thrown away ( 2) .

It m ak es the charge less d ense 3) I t h e lp s t h e a c t ua l sm e l ti n g p ro c ess b e c au se .

t he slag havi ng b een alrea dy m

,
el ted wi ll remel t easi ly and pro mo te the ,

sm el ti ng of the ore i tself ; and i f i t be m ore acid or basi c than the slag that
i s bei ng form ed by th e sm elt i ng m i xture i t wi ll act as an aci d or b asi c flux ,
.

Wi th a furnace runni ng i n a normal way so me ri ch ( foul) slag i s always ,

prod uc ed Thi s i s especi ally the case wh en the last slag i n the furnace i s bei ng
.

tapped and th e bl ast passi ng thro ugh th e tap hole blow

, s out val uabl e par ts -

whi ch enri ch th e Slag i n the p ot ( blow p ot) Then agai n wh en m uch m at te -

.
,

co mes out wi th the slag i t i s li k ely not to settle out perfec tly ,
.

I t used to be th e c usto mto add waste especi ally fo ul slag to all bl ast furnace , ,

charges Wi th fine or es the addi ti o n amo unted to as much as 2 5 p er cent ;

. .

wi th coarse ores i t reach ed 1 0 and 1 5 p er cent Wi th fine ores the use of waste .

slag i s nec essary i n order to k eep op en the ch arge so th at th e asc endi ng gases

pass evenly thro ugh i t and do not form blow holes Wi th coarse ores as -
.
,

first proved by Wm W rai th at Too ele U tah th i s addi ti on is not only un ‘

.
, ,

1
Zt . anorg . Che m .
, 1 9 1 0, mm ,
1 88 .

1
E ng . Mi n
890 , x u x , 706, 735
. J .
,
1 .

1
Austi n, E ng M i n J , 1 905, 86 5, . . . 1 222.

Kneeland, i bid , 1 030, 1 2 1 2 .

D wi ght , B ull A I . . . M . E .
, Ap ri l, 1 91 7, p 4 69
. .

1
Anon, E ng . Mi n J . .
, 1 9 1 6, 01 1 , 1 1 00 .
 324 ME TALL URG Y OF L EAD

th ereby further deco mposed but not wholly as the fused m , ass i s a m i xture of ,

BasO. and BaO ,

The pr esence of sm
. all am o unts of i mp uri ti es e g a t race of ,
. .
,

Fe causes the di ssoci ati on t o b egi n at a lower tem

,
perature In the presence of .

Si 02 the decom posi ti on begi ns at 1 000 C w i th the form

°
,
ati on of si li cat e . .

°
Sub and si ngul o si li cates begi n to si nter at 1 400
-
ses qui bi and tri
sili cate m i x t ures si nter at 1 3 and fuse at The decom posi ti on by
°
P6 20; begi ns at 1 1 00 C and i s not so energeti c as t hat by Si 02 .
, The acti on .

of Pegos i ncreases wi th the amount used and wi th the temperature; th us

1 BaSOr+ 2 Fe303 f uses at 1 350
°
t o a li qui d consi sti ng Of Bao and F8 303 ;
1 BaSO r+ 1 FeO; and 1 BaO + 3Fe303 req ui re 1 4 00
°
for li quefac ti on and even ,

th en the decom po si ti on of BaSO. i s not complete .

Decom posi ti o ns of BaSO , by Slog i n the presence of Fe and FeS have been
formulated by Balli ngz ‘

and by Schw ederz

1
and 3BaSO . +

FeS + 4 SI02 3BaSi 03 + FeSi O a+ 4 SOg The first eq uati on exp lai ns the pres ence .

O f BaS i n a m at te i n t he ab sence of C ; eq uati ons 2 and 3 presupp ose tha t

$ 02 and 0 have an oxi di zi ng efi ect upon Fe and FeS Ordi nari ly very li t tle .

BaS i s fo und i n a m at te ; t here are however cases on record i n whi ch m

’
,
a tt e ,

contai ns fro m4 to 2 4 p er cent Ba . .

Red uct i on of Bas04 to BaS by C begi ns at 600 C and i s co m

°
‘
plete at .
,

t he reducti on by CO begi ns at 6 reaches 98 p er cent at p e r c en t . .

at and i s co m plete at The BaS form ed i s stab le at but

g i ve s off s o m e S a t Th e i n v es t i g at i o ns of W ell s
1
S ho w th at w i t h H t h e

reduc ti on begi ns at 550 C t hat bet ween 600 and 700 much H gS i s evolved
°
.
,
°
,

t hat at 800 t he i ssui ng gas co ntai ns very li ttle H 28 and t hat i n the product
°
,

t he rati o of S t o Ba i s less t han 1 : 1 H e fo und that the reduc ti on wi th CO i s .

complete above and that so m e S i s volati li zed i n th e process ; also that t he

reduc ti on wi th C i s compl eted onl y between 1 000 and

The great fluxi ng p ower of B3 0 i s shown i n Fi g 32 2 Th e for m ati on . .

tem perature Of the basal slag ( Si O, FeO 3 Cao p e r c en t ) .

i s seen to be gr eatly and evenly lower ed thro ugh the r eplac i ng of CaO by
BaO unti l si x ei gh ths of the Geo has been replaced w
-
hen the temperature ,

ri ses agai n The slags for m

. ed are very fl ui d The refrac tory nat ures of .

both MgO and Zuo are readi ly overcome by Ba as not only are thei r form a ,

ti on t em p e r a t ur es lo w er ed but t he i r i rr e g ula r b
,
eh a v i or s corr e c t ed T h us .

BaO w ould be a very desi rable flux were i t not for i ts hi gh speci fic gravi ty ,

whi ch makes the slags heavy and thus h i nders the desi red separati on of mat te
and S lag .

In co m p uti ng a charge BaO i s figured as replaci ng CaO ; Bao = CaO X 0 38

,
. .

Fro mw hat has been sai d i t i s cl ear that all the S contai ned i n Ba504 can not
,

1
Co mpendi umder M etallurgischen Che i e, m St rauss, Bonn, 1 88 2 , p . 89 .

1
B erg H utten mZ 1 886, X LV, 54 7 .

m 3 87
,
. . .

1 JossaKurnakoff, B erg H utten

-
. m
Z , 1 8 79 , xxx v , 38 ; I ron, 1 879 , x . . m , .

1
Mosto wi tsch, loc ci t . .

1
Bureau of Mi nes, B ull 1 1 3, 1 9 1 7 ; J I nd E ng Che
. 1916 v , 770 . . . m
.
, . m .
 S MELTI NG LE AD OR E S I N TH E BLAS T F URNACE

he figured i nto the charge; if 1 0 p er cent of i t i s assu . med to ent e r t he matt e,

m
a ple j usti ce wi ll have been done .

1 44 Blende .
— Thi s i neral ZnS , whi ch i s found wi th m ost lead ores m ,

cause s no end of di fli culty i n the blast furnac es I t i s prac ti cally i nf usi ble ; .

i t i s decom posed by i 1 0n oxi des and si li cates the resul ti ng ZnO enteri ng the
‘
,

S lag to a gr eater or less degree ; m etalli c Fe li berates Zn Most of the ZnS i n a .

blast f urnace charge rem ai ns undeco m posed and enters mat te as well as slag ; i t ,

mak es both less fusi ble obstructs separati on of matte and slag and therefore , ,

causes matte to remai n entangled i n Slag 1

If present to any extent i t for m sa .
,

mushy matte whi ch floats upon th e normal matte and i s di ffi cult to tap ; on
analy si s such a m ush gave Easter Insol Fe 1 9 CaO Zn
1
S 21 .
, ,

Pb 1 0 Cu , p er c en t .

The addi ti on of chalcopyri te m ends m at ters ; but as seen fro mE aster s

1 ’
,

analysi s i ts po w er i s li m
,
i ted .

If blende i s present to a consi derable extent i n the ore thi s m ust be roasted ,

before i t i s smelted ; blast roasti ng leaves a large part of the ZnS unchanged ,

as the Operati o n i s too q ui ck for sati sfac t ory oxi dati on The roasti ng p roc ess .

i s of co urse connec ted wi th loss especi ally that Of Ag Si m monet clai ms that
1
,
.

wi th an addi ti on Of coarsely crushed li mestone to the roasti ng charge most -

of the Pb and Ag pass i nto the more or less al tered li mestone whi ch then can be ,

sep arated by screeni ng fro mthe finely di vi ded zi nc ore The wri ter s exp eri
’
.

ments wi th thi s mode of Operati ng have been anythi ng but successful Iles °
.

avoi ds t he use Of m et alli c Fe for the deco m posi ti on of ZnS as the Zn vapor ,
-

li berat ed favors the formati on of wall accreti ons -

.

The p rogress m ade i n ore dr essi ng has greatly red uced the earli er di fli cul ti es -

enco unter ed by th e presenc e of blend e as thi s i s generally r em oved before ,

th e ore i s sm el ted There exi st however m any d epo si ts i n whi ch gal ena and
.
, ,

blende are so i nti mately associ at ed that a sati sfact ory mechani cal separati on
has not been acco m p li sh e d at l eas t so fa r T w o pr oc esse s w hi ch m ay solv e ,
.

thi s di fi cul t problemare on t ri al at present One i s elec tri c sm el ti ng w hi ch .

,

ai m s t o recover lead zi nc and m at te and to Slag the rem ai ni ng consti t uents

, , ,

of th e ore; th e o ther roasti ng followed by li xi vi ati on wi th H 2504 and elec tro

,

depo si ti on of Zn usi ng i nsolubl e anodes t he lead beari ng resi due goi ng to the
, ,
-

blast f urnace E lectri c smelti ng has not been very succ essful Many smelteri es
. .

have erec ted leachi ng and deposi ti ng plants whi ch work sati sfactori ly ; the
cost Of the sp el ter produced i s hi gh but the cost has to be borne by th e ore , ,

whi ch o therwi se could not be t reated at all The treatment of zi nc lead .

-

sulphi des i s a separate chap ter whi ch i s b et ter di sc ussed und er zi nc than l ead .

1
Pla ttner, B erg H utten . mZ . .
,
1 854 , x m8 , 1 .

1
Iles, S chool M i n Quart .
, 1 89 8, xrx , 1 9 7 .

1
Tr A I
. . . M E , 1 91 5
72 5 . .
,
.

1 Douglas, see B ull A I M E , Ap ril, . . . . . 1 91 7, p .

765 .

H ahn, Mi n Res U S , 1 88 2 , p 34 3
. . . . . .

Kell er, Tr A I M E —
1 89 2 9 3, xxx,
. . . . .
, 71
1
Ann M i n , 1 870, xvn, 2 7.

m
. .

S chool Mi n —
1
.
Quart , 1 89 6 9 7, xv ,
1 8 .
326 M E TALLURC Y OF LE AD

The curves of Fi g 3 2 2 corroborate the prac ti cal experi enc e that ZnO and
.

Mgo i ntensi fy th e undesi rable prop erti es of each other ; th ey also show that
BaO overcomes themreadi ly .

There i s m uch speculati on i n regard to the formi n whi ch ZnO i s pre s ent in

a blast f urnac e slag Fromso m e slags a large percentage of ZnO has been
.

removed by leachi ng wi th N H 40 or di lute H zSO 4 whi ch poi nts to ZnO The , .

i nsol uble p ar t i s consi dered to be ei ther ZnSi O or zi nckiferous m

‘
agneti te
1
,

or i ron beari ng zi nc spi nel ZnA1304 whi ch may separate fromzi nc i ron slags
-
1
,
-

wi th say less than 1 0 per cent A1.o.

, ,
. .

1 4 5 Zi nc Oxi de
.
— Thi s occ urs i n com bi nati on wi th CO, Slog and H20 , ,

in ca rbonate lead ores or i s form ed i n roasti ng blende beari ng sulphi de lead

,
-

o res I t i s i nfusi ble i n carbon heated fur naces but i s reduced by C to Zn vapor
.
-

,
-

at tem peratures rangi ng from1 007 to 1 087 C according to the p hysi eal na ture °
.

of the oxi de and the C and the Zn vapor i s readi ly oxi di zed by CO3 0 and
1
,
-

, ,

H gO vapor
-
.

I t i s di fli cul t to slag ZnO Thi s i s seen in Fi g 32 2 i n whi ch r eplac em ent of . .

,

Cao by ZnO i n the basal slag sho w s gr ea t i rreg ul ari ty i n the c urve Thi s is .

due p robably to the formi n whi ch the ZnO i s present i n the slag as i t m ay be ,

si m ply held i n i gneous soluti on or ZnSi O may have been formed and 1
, ,

di ssolved i n the slag or i t may ha ve combi ned wi th i t i n som , e unexp lained

manner The slags made at Point Piri e N S W and Chi llagoe Queens
.
,
. . .
, ,

land Show co mp osi ti o ns whi ch at first si ght di ffer enti rely from those
,

that are com mon elsewhere as seen i n Table 67 If however the ZnO ,
.
, ,

and A120; are assum ed to form zi nc sp i nel ZnA1304 and th e slag is , ,

recalculated on tha t basi s i t i s seen that the contents of Slog Fco and C2 0 , , ,

Sho w no thi ng ab nor m al The followi ng analysi s of a slag recently m ade in.
,

Colorado gi ves evi dence of Zn bei ng present i n the i nsoluble resi d ue ob tai ned in
, ,

the usual w ay by bo i li ng the chi ll ed sam p l e i n H C l T h e or di nary sl ag dete rm in a .

ti on gav e: I nsol ( S i 02 F e . M n C aO Z n A 130;

Pb Cu The i nsol uble resi d ue w as fused w i th alkali tak en up w i th ,

aci d d ehydr ated the SIG: expelled wi th H F and the resi d ue anal yzed gi vi ng:
, , , ,

Fe CaO Zn A120, I t i s held th at w i th a zi nc bea ring slag -

whi ch contai ns over 6 per cent M101 there i s a tendency to formzi nc sp inel .
,
.

I t has been stated i n § 1 37 that if ZnO i s to enter the slag the percentage of ,

FeO o ugh t to be h i gh and that of Si 02 and CaO low Tab le 67 gi ves com , p o si .

ti o ns of slags whi ch hav e been run m ore or less successfully The furnaces of .

1
I les, S chool Mi n e . t, . 1 898, xxx , 1 9 7 .

H utchi ngs, E ng Mi n . . J .
, 1 903, ucxvr, 959 .

1
H utchi ngs, loc . ci t.

Vogt see below .

m
,
1
Stelz ner Schulze, Berg H ittten Z 1 88 1 XL, 1 4 5, 1 50
-
. . .

“
Vogt , J H L , Di e Si li catsch elzldsung, Dyb ad, Christiania, 1 903, 78,
.
”
. . m w and
“Mi n

eralbildung i n Sch elz assen,

”
Ca m m
er eyer, Christi ani a, 1 89 2 , p 1 99 mm m
m 656 ;
. .

1
Johnston Tr A I M E , 1 9 07, xxx v , 1 9 1 3 , v n, 219 .

melts at
. . . .
,
.

1
Stei n, Z t cuorg Che m 1 907, W , 1 79 , states that ZnSi O . 1 4 79
°
C , ZnSi O. at
mea ured wi th a W anner pyrometer
. .
. .
,

te mpe ratures s .
328 M E TALLURC Y OF LE AD

i t i s f ur ther governed by the percentage of matte that i s formed the hi gh er ,

th e m att e fall the lower the CaO co ntent of the slag

- -
.

Proc esses for the recovery of Zn fromslags i n the formof ZnO have been
p u t i n t o O p e ra ti o n by P a p e W i t te r B a b e
‘
a n d D i v i ne
’ - -
.

1 4 6 Py
. ri te — The m i neral FeSz i s present i n m o st lead deposi ts H eated .

to 700 C wi th excl usi on of ai r i t lo ses one atomof S leavi ng a resi d ue whi ch

°
.
, ,

i s attrac ted by the m agnet

‘1
The atomof S has to be p rovi d ed usually wi th .

Fe to formFeS There are on record cases i n sm

. elti ng angl esi te ore i n w hi ch
the S p assed 06 as 502 and com parati vely li ttle matte was formed .

H enri ch gi ves hi s successful experi ence i n sm

1
el ti ng carbo nate ores at Ben

son Ari z
,
consi sti ng of gal ena ( 1 5 p er cent ) and anglesi t e ( 75 p er
.
,
wi th .

si lver b eari ng p yr i te
-
H e ob tai ned very li t tle m .atte ( 2 0 lb fro m1 3 to 1 4 to ns .

of ore) but consi derable sulphur di oxi de Thi s he exp lai ns as havi ng been
,
.

ca sed by the follow g reac i ons : 2 eSg+ 5Pb804 + S 03 5Pb+ Fe, Si O 4 +

u i n t F i =

9 8 0 3 ; H e sa y s th at th e f u rn a ce ra n ra pi dly a n d
became very hot so that the fuel (coke) had to be cut down from 1 2 5 to 1 1
,
.

p er c e n t t h
. e pr
, e ss ure of th e bl a st b e i n g 1 % i n m erc u ry . .

1 4 7 Chalco pyri te
.
— In the blast furnace th e ai mi s always to carry the
Cu i nto the m at te whi ch i t enters as Cll gs Copper havi ng a greater
, .
,

affi ni ty than any o ther m etal for S w i ll generally tak e up all the S i n the ,

charge to formCq and what i s left i s then avai lable for Fe Pb etc If a , , ,
.

charge does contai n Cu and not eno ugh S to for mCugS som e Cu wi ll be ,

reduced to metal and be alloyed wi th the Pb The alloy hardens si nks to .

,

the bo ttom and clo ses up t he p assag e of the lead well

, Such an al loy con -
.

tai ned Cu c P b c t d A t ( I l )
m
p er en t 47 p er e n a n g 7 1 0 oz.
p er ,
o n es .
,
. .

There i s one case where even w i th su ci ent S to formCugS the Cu com b i nes
wi th the Pb Thi s i s when matte i s co ncentrated i n the blast furnace wi th a
.

hi ghly ferr ugi no us slag The afi ni ti es of Cu and Fe for S and Slog seemto .

become di sturb ed .

If the slag be too basi c th e Fe takes up so m e S and go es i nto the m , at te i n

stead oi sep arati ng and form i ng a cr ust ; th us som e S belo ng i ng to the Cu m ay be

taken aw ay and thi s alloys w, i th Pb Ano ther w ay of ex p lai ni ng th e fac t wo uld .

be that reac ti ons b etween sulp hi des and oxi des of copp er tak e place si m i lar to
tho se of the reverb eratory f urnace and the resul ti ng m etalli c Cu b eco m es ,

alloy ed w i th reduced Pb Whatever m ay be th e th eory the fac t rem . ai ns tha t ,

any excess of Fe has to be avo i d ed i n the slag i f th e Cu i s to be co nc entr at ed i n

the m at te and not p ar tly dri ven i nto the Pb Thi s i s li kely to occ ur when the .

matte contai ns abo ut 1 2 p er cent Cu and dec i d edly so wi th the i ncrease of Cu .

, .

‘
Glitck au f
,
1 1
9 ,0 v 1 , 2 3 7; E ng . Mi n J . 1 9 1 0, Lxxxr
x, 81 9 ; Mi n I nd , . . 1 9 1 0, xxx, 4 53 ,
69 2 ; 4 75
1
Pulsi fer, M et Chem E ng . 1 m 783
9 1 5, x
vm 78
. . .
, ,

1
V alenti ne Tr A I . . M . E .
, 1889 9 -
0, x

m
.
, ,

Geodel, J Gasbeleuchtung, 1 0 .
9 5 x v 4 ,
t , 00 .

Fri edri ch , S ta hl u E i sen, 1 9 1 1 , . xxxr, 2 04 0 .

M etallurgi e
Barth , ,
1 91 2, DC, 2 04 .

1
E ng M i n J 1 883
. .
, xxxvr, 1 79 .
 S M ELTI N G LE AD ORE S I N TH E BLAS T F UR N A CE

1 48. Anti m
mony occurs ei ther a Sb s or an oxi d The Sbs
ony. — Anti s . . e .
.

b hav s on th e whol li ke Pbs but i s much mor e vo la ti le If decom

e e e po sed by ,
.

F th re ul ti ng Sb i m
e e s ore lik ly t combine wi th Pb than i t i to formsp i
s e o s e ss

wi th any ces of Fe tha t maybe present I t mayal o be volati li ed The ox

ex s . s z .

i d i g n rally present a an anti m

e s e e oni ate of lead or i ron and thi s bei ng red uced
s , ,

t an anti m
o oni de combines wi th lead or pei i f any i mad or wi th m
, att s ss, s e, e.

T h tw m
e ai n i nj ur i o us ffec t of anti m
o ony th refor ar th at i t causes loss bye s , e e, e

v olati li a ti o n and i m
z pai r the charac ter of th lead Anti moni al p i ss i s e . s e s

rare and i n maki ng up an or charge n acco unt need b tak en of the mall
, e -
o e s

q uant i ty of i ro n li k el y t b co n um d by t h an ti m o ny I t forms occ asi oonally e s e e .

i n mlti ng anti m
s e ony ki mming ( e s s s e

Two di ffi cul ti es have to be contended wi th i n treating the anti m oni al by

p ro d u c t s o f r e fi ni ng work s i n t he bla st f ur na c e I f t h e s la g co n ta i ns b ut li t tl e .

Fe m ,
uch anti m ony and lead are volati li zed if ri ch i n Fe some spei ss i s li kely to
for m w hi ch ei th er separates ca usi ng the loss of the anti m
, ony or becom ,es m i xed ,

wi th the slag maki ng i t ri ch A ferruginous slag i s generally preferred to one

,
.

that i s cal careo us .

1 4 9 Arseni c .
— Arseni c occurs very frequently i n argenti ferous lead ores and
.

must not be neglected i n comp uting a charge It causes lo ss by volati li zati on .

'

and co m bi nes wi th the Pb but no t to such an ex tent as Sb as i t has a , ,

g r ea t a ffi n i ty for F e a nd i s li k e ly to for m a s p ei ss I f i t i s n ec es sa ry t o co ns i d e r .

t he for m ati on of spei ss i n m aki ng Up a charge i t i s advi sable to figure 5 ato m s ,

A s : 1 a tom Fe as thi s m i xture i s m

, oderately fusi ble and pretty flui d when
mel ted does not readi ly form hear th accreti ons and retai ns only very few
, ,

sho ts of lead I t show s large cleavage planes si m

. i lar to sp i egel i ron w hen
broken A spei ss contai ning more or less Fe than called for by the suppo sed
.

formula FebAs i s not as easi ly fused nor as fl ui d when melted ; i t i s th erefore ,

mo re li kely to formaccreti ons and to hold lead i n suspensi on .

In m aking up a charge if the ore does not contai n too m uch ar seni c i t i s pos
, ,

si ble to avo i d p roduci ng any spei ss at all by assi sti ng p ar t of the arseni c to pass

06 wi th th e gases and the rest to co m bine wi th the lead and enter the m at te .

Thi s can be done by m aki ng the ch arge op en by c ut ti ng dow n the fuel and ,

ther eby di m i ni shi ng the reduci ng ac ti o n and by changi ng the p ro p or t i o ns of FeO ,

and CaO i n the slag It w as once h eld th at by cutt i ng do w . n the Fco the re ,

q u i re m e n t of S i 0 2 for FeO t o for m sla g wo uld b e so gr e a t t h at th e r e wo uld b e

no ne lef t for the As to form spei ss ; and furnaces have b een run successf t
on thi s b asi s On the o ther hand Breth er ton has show
.
‘
n th at i ncr easi ng the ,

CaO content i s very efl ecti ve i n co unteracti ng the form ati o n of sp ei ss

'

-
In .

sm el ti ng tw o ores one w i th Pb Fe ,
Mn Zn Cao Mgo
SIC: A120; As S trace ; the o th er w i th Pb Fe Zn
CaO Mn none Mgo none Si 02 30 As trace S trace and m ,
aki ng a slag , , , ,

runni ng hi gh i n Cao and MgO he produced no spei ss whatever The hi gh , .

content of MgO of course rai sed the formati on temperature of the slag and
, ,

1 Tr A I
. . . M . E .
,
1 91 5, 730 .
330 ME TALLURGY OF LE AD

wi th i t the temperature of the f urnace whi ch i n i ts turn grea tly favored the ,

volati li za ti on of As through the open charge .

On acco unt of the hi gh m el ti ng po i nt of spei ss i t i s necessary to have a hi gh -

tem perature at the tuyeres morder to prevent the spei ss fromchi lling esp eci ally ,

as i t flo ats on the lead and 13 covered by m at te W i th consi derable amounts .

Of spei ss i t m ay be necessary to ai mfor a sesqui sili cate slag of hi gh form

, ati o n -

t em perature ‘
.

Wi th a spei ss crust form i ng i n the hear th of the furnace scrap i ron i s fre
-

q uently added to the charge to li quefy the crust Thi s i s useful if the spei ss .

does not contai n enough Fe; i t canno t do any good if the accreti on has been ,

caused by an i nsuffici ent temperature at the tuyere level or by havi ng kep t too -

low the level of the lead i n the cruci ble .

1 50 Calculati on of Charge, General

.
1 — In calculati ng a charge for the .

blast furnace there have to be consi dered the wei gh ts of charge and fuel the ,

sl ag b est sui ted for the ore the am ount of lead the charge i s to contain the ri ch , ,

ness of th e lead b ulli on that i s to be produced and th e quanti ti es of spei ss , ,

matte and slag that wi ll ensue A complete calculati on wi ll gi ve full informa

,
.

ti on on all these poi nts .

The w ei ght of charge to be i ntroduced at a tim e i nto the f urnace i s governed

i n part by the am o unt of fuel req ui red to smel t i t and the latter by the th roat ,

ar ea In hand feedi ng ch arges whi ch contai n fine ore

.
-
s the sm allest am o unt ,

that m ay be used i s that whi ch co m pletely covers the precedi ng charge so as to

forma di stinc t layer H ahn ascer tained the amo unt by placi ng on the feed
1
.

floor a w ooden fram e of the sam e area as the thro at filli ng i t wi th coke to form ,

a layer and th en wei ghi ng th e cok e

,
If charge and coke are m i xed th ere i s .
,

danger of the heat creeping up through the poro us coke; if the two are kep t
1

sep arate
1
the ascendi ng gas enteri ng the porous cok e layer w
, ill be di stri b uted
evenly over the whole area and act efi ecti vely upon the overly i ng layer of ore ,

1
H enri ch, E ng Mi n J 1 883, 1oom, 2 1 1 .

M i n J 1 88 7 xm, 1 1 1 , 1 89 2 ,
. .

1
Murray, E ng . .
, 2 81 .

Newhouse, —
S chool Mi n Quart 1 88 7 88, 111 , 3 73
m
. .
,

Furman , op 89 2 9 3,
. ci t .
, 1 -

, 1 34 .

Furman H van F Pard0e, W D “Manual Of Practi cal Assa i n W iley, NewYork

y g,
-
. . . .
,
,

Sai nt D i zi er , C olo S tate S chool Mi n S c Quart , . . . . 1 893, II ‘

, 50 .

H ersa m ( Grap hi cal Method) , Tr A I M . . . .

340 .

Chauvenet, Mi n Reporter, 1 907, W I , 56, 1 90, 2 1 2 , 2 64 , 3 78, 39 6

. .

Chauvenet, R
“ ”
Che i cal Ari th eti c and Furnace Charges, Li p p i ncott, Phi ladelp hi a ,
. m m
1 91 2 , p . 2 07 .

“M etallur i cal Calcul ati ons ” McGrawHi ll Book Co NewYork 1 1 8

Ri chards, J W . .
, g , , 9 ,
-

P 59 3
Earl, E ng Mi n J . . 1 909, m m 96 , 2.

von Schli p penbach , M etall . u Bra , . 1 91 5, x rr, 399 .

D udley Met ,
. Che m E ng . .
,
1 91 7, xvr, 8 7, 1 29 .

1
Tr I nstMi n Met 1 899 90
.
— VI II , 2 6 7 .
,
.
,
. .

1
Austi n, Mi n S c Press 1 90 7 xcrv 6 1 . .
, , ,
.

1
D wi ght, Tr A I M E 1 902 xxx n . . . . .
, , ,
6
3 3 .
332 ME TALLURGY OF LE AD

T AB LE 69 — CO RRE CTE D
. AN ALYS E S or CH ARGE -
CO MPO NE NTS

The Zn present i s figured as enteri ng the slag i n whi ch i t replaces an eq ui ,

valent amo unt of CaO tho ugh i n reali ty perhaps only 80 p er cent do es t hi s ;
, .

the r est b ei ng volati li zed or enteri ng the lead b ulli on matte and fl ue dust ,
-
.

No acco unt i s taken of the losses i n Pb Ag and Au The three m etals are , .

assum ed to be coll ec ted i n the l ead b ulli o n tho ugh as a m atter of f ac t one , ,

part i s lost and ano ther goes i nto i ntermedi ary produc ts especi ally m
,
at te and ,

flue dust
-
.

It wi ll be no ted that the analysi s Shows no F If thi s were p resent a cer .

,

tai n am o unt of Ca equi valent to that requi red by F to formCaFg would be

, ,

rendered unavai lable as b asi c flux .

The ac tual devi ati ons fro m assum ed fig ur es vary wi th th e ch arac t er of

ore and slag and th e w ,

orki ng of the furnace so that the resul ts of a comp utati on ,

usually do not corr espond acc urately wi th those ob tai ned fromthe fur nac e at ,

l east wi th a newore The sli ght devi ati ons are ho wever easi ly correc ted when
.
, ,

the wei gh ts and analyses of the fir st prod uc ts h ave b een ob tai ned .

The sl ag chosen for the charge i s the typ e E (La Pi se E i lers) Table 64 w i th -

, ,

Si 02 30 FeO 4 0 CaO 2 0 R0 1 0 p er cent

, , ,
.

The charge S hall wei gh 1 000 lb and contai n 1 0 p er cent foul sl ag of th e . .

sam e co m posi ti on as the one that i s to be for med The wei ght of the cok e .

sh all be 1 5 p er c ent of that of the ch arge . .

The tw o fl uxes used are i ro n ore and dolo m i ti c li m est one The anal ysi s .

of the for mer shows : Si O,; 4 3 FeO MnO CaO .

p er c
, ent ; t h at of th e .

l at ter : Si 02 FeO CaO Mgo p er c en t .

The cok e c ontai ns 1 0 p er cent ash w hi ch consi sts Of Slog .FeO ,

CaO MgO A120. p er c e nt .

Befo re b egi nni ng the c alc ulati o n i t i s necessary to bri ng the di fl erent slag ,

formi ng compo nents of ore flux and cok e under the three mai n heads of Si O ,
, , ,

Fco, and CaO .

Ferro us and manganou

oxi des FeO and Mno have nearly the same mole
s , ,

cular wei gh ts 7 2 an
, d 7 1 h e n c e t h e t w o ,
o xi d es a r e si m ply ad d ed In t h e .

deco m p o si ti o n of P b S m e tall i c F e i s t
,
h e p r i n c i p al r ea ge nt h en c e F eO h as t o ,

be ch a n g e d i nt o F e as sho w n by Fe O X Zé = F e or F e O X 777 Fe
0 =
,
. .

Magnesi a MgO and bary ta BaO are generally figured as rep laci ng eq ui
, , , ,

val ent amo unts of CaO al though some metall urgi sts obj ect to thi s p roced ure
C O
a M g O =
5 6 4 0 ,
i n t h e s a m e m a n n er C aO = B aO X 0 4 ,
. .

Zi nc oxi de Zoo i s figured as replaci ng CaO i n the slag : CaO = ZnO X 0 7

, ,
.
,

th us c ut ti ng down the CaO content of the slag wi th the i ncrease of Zuo -

.
 S MELTI NG LEAD ORE S I N TH E BLAS T F URNACE

The ana lyses of ore, flux , and coke ash changed -

, as i ndi cated , are gi ven

i n Table 70 .

In figuri ng the charge fo ur pr eli mi nary calc ulati ons have

, to be made
1 . Th e mount a of available FeO and Fe i n th e i ron ore .

2 The amount of Fe eq ui r red by the As to formthe supp osed FegAs .

q ui red to com
.

munt Fes w
m
3 The . a o of Fe re bi ne to i th the S not t aken up by the
C u as C .

4 . The a mount of flux equi red f r or the 1 5 lb . of ash in 1 50 lb . coke .

Avai l able FeO and Fe i n I ran Ore — I n the slag, 30 Si 02 re qui re 4 0 FeO . In 1 00 lb .

i ron ore there are lb Si 02

. . These req ui re
Si 02 FeO = 3 0 : x,

x = FeO .

The i ron ore cont ai ns p er cent . FeO ; deducti ng gi ves lb . v

a ail

a ble FeO, or $6 X FeO = lb . v

a ail able Fe, i n 1 00 lb i ron ore . .

Arseni c and I ron — . 1 00 lb lead . ore cont ai n lb As . .

As : 5F =
e 75
Fe .

H ow much i ron ore will furni sh thi s ?

I ron ore a vai lable Fe= 1 00 :
=
y 3 5 lb i ro n ore . . .

Copper, I ron, and S ulphur — 1 00 . lb lead . ore contai n lb Cu . .

2 .
9 : x,

n = o 73 . S .

O f t he lb S . cont ai ned in 1 00 lb l ead

. ore, lb i s
. re ui red q for the Cu; the
di fi erence, lh .
,
must be combi n d wi th e Fe .

H ow uch iron m ore will f urni sh this ?

Iron ore avail able Fe = 1 00 : 53 . 2 =z
z= 1 2 lb i ron . ore .

There are re qui red for the As and S in 1 00 lb lead . ore, 3 . lb i ron
.

o re . Th ese cont ai n lb Si 02,. lb FeO , . and lb CaO . . Only the non

a v ail able mbi nati n wi th Si 0 i n th rati of 30 Si 0 40 FeO
FeO , that i s, t he FeO i n co o 2 e o 2 .

en t r th lag vi
e s lb ; th rem
e sai ni ng lb v i lable F O havi ng b n u d
,
z .
,
. e . a a e ee se

up a F to c m bi ne w
s i th A and S t f m p i
e o and m tt s o or s e ss a e .

The lb SIG: hav e to be supp li ed

. wi th CaO i n the rati o of 3 0 Si Oz 20 CaO
Si 02 : Ca0 =
30 : : x,

n= o 4 s lb CaO . . .

T his mount may be c

a onsi dered to be balanced by t he lb CaO p resent i n the .

lb i ron ore
. . If t hi s were not t he case, t he lb CaO woul d have to be sup p li ed f ro
. m
li mestone .

Li mt es one CaO 1 00 y
Furnace -
men cal culat e the a munto s of FeO and CaO necessary t o flux the Si 02 of

a coke ash or a si li ci ous lead ore ei ther by th e algebrai c

-
mthod e , usi ng equati ons wi th
t wo unkno wns , or by t he app roxi mate syst e mu i ng p rop o ti s r ons, whi ch i s the me or

co mmon mode of p rocedure .

334 ME TALLURC Y OF L E AD

The Algebrai c Method i s tak en up first .

Coke ash-
— Starti ng w
. i th 1 00 lb coke .
-
ash, the a munts of i ron
o ore ( )
x and li m
e

stone ( )
y necessary for fluxi ng Si 02 i n th e $ 0, 4 0 FeO : 2 0 C2 0 can rati o of 3 0

be found by exp ressi ng the am ounts of FeO first i n t er s of Cao, then i n term s of m
Si 02, and finally p utting these quanti ti es equal to each other, w hen x and y can be
easi ly cal culat ed .
a
Let then FeO : Fe0 =
X CaO ; and FeO SIC :

a c, Fe f x 510.
2
The necessary analyt i cal data are gi ven i n Table 70 .

T ABLE — CORRE CTE D AN ALYS E S or CORE Asa AND FLUx E s

70 .
-

M ateri al

a
( )
1 Fe0 =
b

x= 1 .
5 4y
2

( 2)
0

x= 39 .
77
—0 0 1 3y . .

( 3) 1 .
5 4y
2 -
o o r3y . .

y lb li. mestone ,

n = l b i ron ore
3 o4 . . .

Ore — . Starti ng wi th 1 00 lb lead . ore, the nece

s sary analyses

TAB LE 7 1 .
— CORRE CTE D AN ALYS E S TO R LE AD ORE AND FLUX E S

M ateri al

0
( ) I FeO = CaO ,
b
0

x=

x= 3
—o o r3y
. .
336 ME TALLURCY OF LE AD

If the slag rati o i s to be Si 02 30 : FeO 40 : CaO 2 0 the 2 1 6 lb Si O , wi l l ,

.

ca l for
l 2 1 6 X% = 2 88 lb eO and
F 2 1 6 =
X % 1 44 lb CaO i n th e slag
.
,
Th e . .

CaO i s seen to b alanc e the corr espo ndi ng co lum n i n the table but th er e i s ,

l ef t a balanc e of — 2 8 8 = lb FeO i n exc ess Th i s wi ll be r eq ui r ed . .

to furni sh the Fe for the sp ei ss and m at t e .

In 1 000 lb charge there are contai ned . lb or p er c e n t P b T hi s . . .

1 04 5 lb Pb coll ec t s th e
. . oz Ag henc e the lead b ulli on w i ll assay 2 4 3 oz .
,
.

Ag p er ton p resup posi ng t hat all the Ag has entered the Pb

,
'

The charge contai ns 2 5 lb AS whi ch w i th lb Fe forms . lb . . .

spei ss .

The lb Cu of the charge req ui ri ng . lb S wi ll form lb Cugs ,

.
,
. .

Ded uc ti ng the lb S fromthe to tal of lb leaves 1 8 5 lb w

. hi ch wi th .
,
. .
,

lb Fe gi ve
. lb FeS The to tal matt e formed wi ll be
, . .

lb Thi s p resupposes that th e matte i s free fro mPb; ac tually i t contai ns

.

1 0 1 2 p er cent Pb
— Table 72 furth er Sho w
. s th at t here are 1 0 p er cent S lag
. .

and 1 5 p er cent cok e on the ch arge . .

It w i ll be no ti ced that i n sum mi ng up the resul ts of the calculati on the ,

wei gh t of the coke ash ( 1 5 lb ) has b een i ncl uded al though not that of the coke
-
.
,
.

Thi s i s not usually done by lead and copp er sm el ter s w ho cont rary to the p rac ,

ti c e of th e i ro n sm el ter i ncl ude only ores and fl uxes and not th e f uel
,
In thi s ,
.

i nstanc e the cok e ash has b een added for the p urpose of bri ngi ng toget h er i n
-

the table everythi ng that i nfl uences the for m ati o n of the slag .

In m aki ng up the charge for the blast f urnace the m oi st ure has sti ll to be ,

consi dered If the lead ore contai ns for i nstance 5 p er cent of moi st ure
.
, ,
.
,

53 1 lb of
. m o i s t o re w i ll h av e to b e u s ed t o corr espo nd to 5 5
0 lb of dry or e .

Moi st Ore : Dry Ore = 1 00 : 95 : x 51 0 ; x = 53 1 .

The sam e i s the case w i th fluxes and fuel .

I t i s to be no ted t hat figuri ng a charge accordi ng to the algebrai c m ethod has

one great advantag e over the m ethod next to be descri b ed vi z th at i t shows i n ,

.
,

what proporti ons any three classes of si li ci ous ferrugi no us and calcareous ores , ,

are b est m i xed so as t o beco m e self fluxi ng -

.

1 52 Calculati on of Charge by th e M ethod of Proporti ons

.
— Ore fl ux fuel , , ,

and slag are the sam e as i n the pr ec edi ng co m p utati on .

The preli m i nary calc ulati ons such as bri ngi ng the di fl erent co m po nents of
,

ore fl ux and f uel under the h eads of Si 02 FeO and Cao are m
, , ade as b efore , , ,
.

The to tal wei ght lb ) that the charge i s to have and wi th i t the percentage
.
,

of f uel ( 1 5 p er cent ) and slag ( 1 0 p er cent ) to be added are fixed The avai l
. . .

able FeO and Fe of the i ro n ore are deter m i ned as i n § 1 51 .

Tw o c alc ulat i o ns are nownec essary to deter m i ne the am o unts of i ro n ore and
li mestone req ui red by the coke ash and by the ore -
.

Coke ash — -
The analyses of the ash and th e tw
. o fl uxes i ron ore and ,

li mestone are entered i n Table 73 The 1 50 lb of coke co ntai n 1 5 lb of

, . . .

ash ; for these the totals of Si 02 FeO and CaO are figured and entered i n , ,

the tabl e .
 S MEL TI NG L EAD ORES I N TH E BLAS T F URNACE

There are present lb of . Si O, ; how much FeO i s requi red

Si O, : FeO :
=
n 8o . lb . FeO necessary ;
lb . FeO i s present .

Th e di fi erence, y=
=4 lb FeO to be added
. 0 . .

To find the nec essary i ron ore

Iron ore Avai l able FeO : 1 00 : s

z= lb i ron ore . .

They are entered i n the table; th ei r to tal po und s of Si 02 Fco and CaO , ,

a re figur ed and al so enter ed .

To the previ ous am o unt of lb Si 02 has been add ed by the i ron ore .
, ,

lb Si O g maki ng the to tal Si 02

.
, lb for whi ch li mesto ne has to be provi d ed ,
.
, .

H owm uch CaO i s req ui red ?

Si Og : CaO : : 30 : 2 0 :
=
u 4 . 2 lb CaO nec essary ;
.

lb . CaO i s present .

The di fi erence, v= 2 5 lb CaO to be add ed

. . .

To find the nec essary li mestone (neglecti ng the mall amounts of Si O s , and
F eO i t co ntai ns)
Li m ton es e: CaO : 1 00 : w: 2 .
5,
w= 4 6 lb li mestone
. .
,

whi ch are ente e r d wi th the pounds of CaO they bri ng t o the sa l g .

TAB LE — CALCU LA1 1 0N OP FLUx E S rO R CO RE ASE

73 -

Materi al

Na me

The lb ) and li mestone

wei gh ts of i ro n Ore lb ) are prac ti cally the . .

sam e as th ose fo und by the algebrai c m ethod and

For the req ui red slag r ati o of SlO g 30 : Feo 40 : C2 0 2 0 there wo uld ,

then be r eq ui r ed to acco m pany the Si O, X 36 lb FeO and ,

.
,

X lb CaO whi ch check wi th the amounts sho wn i n the table

.
,
.

D educ ti ng lb ( the sumof the slag and coke ash wi th i ts iro n ore
.
-

and li mes t o ne) fro mthe to tal wei gh t Of the charge of lb gi ves lb . .

lb as calc ulated in § 1 51 to be m
,

as com pared wi th .
,
ade up by the ore ,

and i ts fl uxes .

22
338 ME TALLURGY OF L EAD
—
Lead Ora Table 74 i s lai d out for the ore ; the analyti cal data are entered ,
and the calculati on i s made on a basi s of 1 00 lb .

1 The am
. o unts of i ron ore req ui red ( 1 lb ) by the As and S are calc ulated .

as i n § 1 51 and the r esul t s are entered i n the tab le

,
.

2 Th e 1 00 lb of ore contai n
. . lb Slog for whi ch the necessary FeO .
,

has to be provi ded

Si n FeO : : 32 6 : x .

x = 43 5 lb F eO n ec essa ry ; . .

lb FcO i s pr esent . .

Th e di fi n
e e ce y
r = 2 4 4 lb FeO to be add ed
, . . .

To find th e nec essary i ron ore :

Iron ore : Avai lable FeO : 1 00 : z

s = 3s s . lb . i ron ore .

3 . To the lb . of the ore have been added fromthe two

Si 03
of i ro n ore, lb Si 03 m aki ng the to tal of
. lb of , .

whi ch Cao has to be provi ded

Si 03 : C3 0 : : 30 : 2 0 :
=
u 2 lb CaO necessary;
3 . 2 .

present lb . CaO i s .

The di fi r n ==
e e ce v 1 1 4 lb CaO to be add ed
,
. . .

To find the necessary li m s t one ( negl ec ti ng th e sm

e all am ounts of Si O, and
FeO i t contai ns)
Li m estone : CaO : 1 00 : w:
w= 2 1 1 lb li mestone . .
,

whi ch i s entered upon th e table .

Check i ng the c alc ula ti o n fromth e slag rati o $ 0; 30 : FeO 2 0 : CaO 2 0 , ,

shows for lb Si 03 a req ui rem ent of

. lb FeO and of .
,

lb Cao The Cao checks wi th the figure i n the ta ble ; th e

. .

FeO l eaves an exc ess of lb FeO wh i ch i s eq ui v alent to .

,

lb Fe and i s need ed to supply the

.
,
Fe for the sp ei ss and th e lb .

Fe for the m at te .

TAB LE 74 — CALCU LATION or w as 2 011 Law O n .

Materi al

Na m e

1 00

I ron ore for As and S . 15 . 6

Iron ore for
Li mst
e one . . 21 1
340 ME TALLURGY '
OF LE AD

or decompo si ti on of Met S by metal begi ns at about 900 C ;

Preci pi tati on, .
,
°
.
1

the veloci ty of reac ti on i ncr eases w i t h the tem perature and reach es i ts m axi m um

at tuyére level or at fro m 1 1 00 to 1 2 00 C

°
-
The r eversi bili ty of the rea c ti on
,
.

counteracts the complete decompo si ti on of

Met S ’
.

The behavi or s of the leadi ng com ponents of a lead charge under furnace
condi ti ons have been outli ned i n § 2 1 4 1 and § 1 34 1 50 There remai n to be con
— — .

si dered the changes Agas and AgCl ( BrI ) m ay und ergo and t he efi ects m
'

ix ,

tures of C03 and CO i n th e asc endi ng gas current have upon C and Fe 0 as ,

well as of C upo n Fe O , , .

An and Ag whi ch m C resp ec ti vely format 903

° °
el t at 8 1 5 and 960 ,
.
,

mi xtures contai ning from to p er c en t A g wh i ch sep ar a te i n t o tw o .

,
°
layers and at 804 C an eutecti c
’
, .

wi th 99 p er cent Ag, s The . .

sulph i d e AggS heated wi th Pho , ,

i s readi ly deco m p o sed : A g +, S

2 Pho 2 ( Ph Ag) + 803 ? heated .

wi th S i des i t i s lik ely to form

.

3
60 -

503 e u t ec ti c m i x t ur es an d so l i d s o lu
ti ons ( see Mat te h ea ted

5
,

wi th metals havi ng a stro nger

so

affi ni ty for S th an Ag i t i s decom

«
,

posed onl y ln par t for si milar ,

r ea s o n s Thus Mostow i tsch ‘

.

for mulated i ts behavi or wi th Pb by

FIG 324
— Eq ui 1i bfi tl mdi agra m of Fes s and chlori de AgCl whi ch i s
The
mi tu
, ,
C in x re
s of C0 and CO, ( Bauer G lassner,
readi ly vola ti le i s reduced to the
-

,
Boudouard .
)
metalli c state when heated wi th
Zn or or Cu or Pb or Sn or Sb or Bi
Fe .
‘

Au foll ows Ag i n m o st fire processes -

.

The rea c ti on C02 + C< 2 CO begi ns at 550 C but i s li kely to be i nco m

— °
’
plete .
,

on acco unt of the reversi b i li ty of th e eq uati on The research of Boudo uard °

.

has shown that red uc ti on stops at 650 C wi th a gas m

°
i xture of C02 6 1 + CO 39 .
-

0
°
p er c en t vol a t 800
. w i t h C 3 7.
+ CO 9 3 p er cent ; at 95 0 wi t h C02 4 + C 0 9 6 .
°

p er c e n t Hi s e q ui l
.i bri u m di a gram for di fl’
erent v o l u m e s of C03 and CO i n
co ntac t wi th C i s sho wn i n curve I of Fi g 3 2 4 If the curve i s r ead fro mri gh t . .

to left i t w, i ll gi ve the condi ti ons of equi li bri umof the ascendi ng gas current .

At 900 or say 1 000 C no C03 can be i n eq ui li bri umwi th CO i n th e presence

°

1
Schli tz , loo . ci t .

Bi ssett , Tr Che . mS . oc. , 1 9 1 4 , CV, 1 2 2 3 ; J . I nst M et 1 9 1 4 , m

. .
, ,
2 93 .

Percy, J, . Metallurgy of Silver and Gold,

”
M urray London, , 1 880, pt . 1, p 38. .

M et Chem E ng
. . .
, 1 9 1 6, x v, 703 .

Percy, op ci t . .
, p 93. .

‘ Ann clai . m pl y . a s ,
1 9 1 0, xxi v, 2 8 .
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URNACE

of mount of C h nc the C at th tuyer ough t to burn to CO

a sufi ci ent a ,
e e e es .

If n v r th less m
, e euch C0 i form ed i n th e lea d bla t furnac e thi
e i s ca used
, 2 s s , s

by the mall amount of C pr ent at the tuyér level whi ch canno t reduc all
s es e -

, e

t h C0 for md and by th
e c 2of ai r blown i n whi ch o i di e a larg par t
e , e ex ess ,
x z s e

of the CO formd Th mi tur of C0 and CO ri e qui ckly i nto the cooler

,
e . e x e 3 s s

regi ons a bove .

At 800 bout 4 ft above the tuyeres 1 0 p er cent vol C03 i s held i n

°
C.
, a .
,
. .

eq uili b ri umas r egard s C by 90 p er c ent vol CO ; at 5 about 1 5 ft abov e the . . .

t uyer es 90 vol C02 + 1 0 vol CO have no effec t up on C

, . B elow 500 or . .

when CO i n the p resence of C canno t be i n equi li bri umwi th C03 the reac ti on ,

of carbon depo si ti on 2 CO C02 + C may be exp ected wi th oxi des di fi cult of

=
, ,

red uc ti on .

Curv e II exem p li fie s th e li m i t s of th e r eac t i o n

At 550 C a gas of the com m
°
p o s i t
. i o n 5 6 vol C 0 2 + 44 vol C O i s i n e q ui li bri u . .

wi th Fego4 A gas wi th 60 vol C02 + 4 0 vol CO contai ni ng an excess of CO;

. . .

over that demanded by the equi li bri umwill show a tendency to be changed
i nto 56GO2 + 44 CO that i s to gi ve off 0 ; hence i t wi ll act oxi di zi ngly up on , ,

Fezol A gas of the com

. po si ti on 50 vol C02+ 50CO for analogo us reasons .
, ,

will have a reduci ng effect .

Wi th r egard to C bo th gases wi ll have an oxi diz i ng b ent at 5 ,

Curve I II i n the sam e m anner gi ves the li m i ts of the reac ti on FeO + CO

a gas of the com posi ti on 39 vol C03 + 61 vol CO will be
'

z i Fe l COg
-
At 7-
. . .

i n eq ui li bri umwi th FeO At poi nts A and B only that i s at 680 and 700 C
°
.
, .
,

can there exi st a perf ec t e ui li bri umb etw e e n C C 0 C 0 F 0 ( F O ) a n d

q 3 e 3 4 e , , , ,

FeO ( Fe) ; at o th er tem peratures i t i s di sturbed If the i ro n ore used as fl ux .

2 9
were solely Fe304, the rati o wo uld have to represent val ues lyi ng above
CO ;
the full drawn li nes -
.

I n applyi ng the foregoi ng to the ch emi stry of sm el ti ng i n the lead b last fur

nac e i t i s conveni ent to consi der separately th e qui ckly ascendi ng gas c urr ent
,
-

and the slowly d escendi ng ore ch arge -

.

1 54 The Ascendi ng Gas current

.
— There have not b een p ubli shed any -

analy ses of gases form ed at the tuye res Schertel cal culates fromhi s analyses
l
.

of gases passi ng off at the throats of Frei berg lead blast furnaces that at the tu
yeres C burns mai nly to C02 Fi g 3 2 5 represents averages of a large number . .

of gas analyses made i n 1 905 froma Colorado blast furnace the slag of whi ch ,

gave wi th a Wanner p yro meter 1 1 2 0 C when flo wi ng fromthe tap hole The °

.
-
.

ab sci ssa: represent p ercentages vol um e of C03 CO and O ; the ordi nates gi v e , ,

in feet the verti cal di stances fromthe tuyeres at whi ch the sam pling tube was -

i nser t ed At 1 ft above the tuy eres th e curves show 8 vol CO 1 2 C02 and
. . .
,

free 0 Table 75 gi ves analyses of waste gases p assi ng off at the throats of
.

furnaces at Frei berg Sax ony and at D enver and Pueblo Colo At the , , ,
.

Frei b erg works the ore ch arge co nsi sted of slag roasted lead ore slag and - -

, ,

burnt pyri te; the slags formed contai ned p er c en t Ca O and p er cent . .

‘
Proi b J ahrb , . . 1 880, 3 7; B erg H i . mmm Z . .
,
1 880 , m m 85 ,
.
342 M E TALLURGY OF LE AD ’

Mgo so that the CO, fromdolo m

,
i ti c limestone pr esent co uld not ha ve muc h
i nfl uence upon the Cog content of the gas At the Colorado works bedded -
.
,

mi xtures of rawand roasted ores were smelted wi th hi gh CaO slags -

.

15 20
Perce nt Vol u me
FIG 3 2 5
. .
-
Percentage
s of 02, CO; and CO: i n lead blast furnace gas at di fl erent heigh ts above

tuye re level
-
.

TAB LE 75 .
-
ANALYS E S
. or W AS TE GAS E S or LE AD Bu sr runn '
3s
er
-

75 -
30 75 - 20 75 5 - -
9 79 6 75 s
- -

( a) Sch ertel lot . . ci t

.
( b) Iles M W . . .
, p ri vat e co mmuni cat i o n. ( c) Dwi gh t A S. . .
, p ri vate co mmuni cat i o n .

wi ll be no ted that the excess of C03 over CO i n the gases i ssui ng from
It
the throats of the furnaces r epresented i n Fi g 3 2 5 i s m uch larger than t hat i n,
.
,

the gases taken 1 ft above the tuye res ; hence C w i l l have been largely b urnt
.

to C0, by contac t wi th oxi des easy of reduc ti on and CO wi ll have act ed m ore ,

or less as a red uci ng agent Table 75 shows that the rati o of CO, CO wi th the .

low CaO slags of Frei berg i s hi gher than w

-
. i th the hi gh CaO slags of Denver -
.

It m ay be assum ed th at at the tem

°
perature of the tuyere regi on of 1 1 00 -

C the C of the coke w i ll burn m ore to C02 than t o CO The m

°
1 2 00 .
,
i xtur e .

of C02 CO and N ( om
, i tti ng possi bl e H and $ 02) ascendi ng i n the furnace
, ,

shows Fi g 32 5 an i ncrease i n CO, and a corresp o ndi ng decrease i n CO

, .
,
At .
344 M E TALLURC Y OF LE AD

Zone ch r f i o — ° °
1 f o Preparatory H eati ng, a g e e d nt1 00 t h
400e C -
The
furnace gi ves up i ts hygro scopi c water then that whi ch i s chem i cally com bi ned ;
,

clayey materi al li moni tes and other hydrates gi ve up at 400 onl y par t of
, ,
°

thi s water The evaporati on of water ab sorbs heat and thus assi sts i n keepi ng
.

the top of the furnace cool .

— The decom
° °
2 Upper Z one of Reducti on 400 700 C
. posi ti on of hydrates
,
-
.

conti nues the di ssoci ati on of carbonates and of some sulp hates begi ns Th e
, .

reduci ng efl ect of CO whi ch theoreti cal ly begi ns at 2 00 C becomes noti ce

,
°
.
,

able onl y at abo ut and i ncr eases w i th ri se of tem perature up to abo ut

It w i l l therefore be an acti ve agent i n red uci ng PbO com pletely to Pb ,

and Pb804 par tly to PbS ; i t w i ll al so start the reduc ti on of Fezos The C of the .

°
coke whi ch begi ns t o act reduci ngly at about 400 C and i ncreases as the
,
.

tem perature ri ses wi ll change PbO comp l etely i nto Pb and PhSO4 partly i nto
, ,

PbS ; i t wi ll assi st CO i n i ts red uc ti on of Fea and wi ll transformC0, of the ,

g as c urr en t i n t o C O T h er e w i ll f ur t.h e r ta k e pl a ce r ea c t i o ns of P h S O ; a n d
Pho wi th PbS setti ng free Pb and $ 03 ,
.

3 L ow
. er Z o ne of R ed uc ti o n 700 —
9 0 0 C — Th e re a c ti ,on s s ta rt ed
°
i n th e
°
.

precedi ng zo ne conti nue and are i n part com p l e t ed ; t h e e fi ec t of C b e co m es

more marked than that of CO The CaSO4 i n blast roasted ore as well as .

Ba804 i n rawore are m ore or less red uced to CaS and BaS to be di ssolved
l ater on mai nl y by the slag The di ssoci ati on of carbonates i s abo ut com . pleted ,

CaCOa at The uni on of Slog w i th unred uc ed PbO and PhSO4 begi ns ,

as does th e deco m posi ti on of Pbs PbAs PbSb. by Fe; sulphuri zati on of Cu , , ,

begi ns about at the same t emperature Mat te of eutecti c composi ti on begi ns .

to sof ten E very thi ng i s prepared to be li quefied and to b ri ng to co m

. pleti on
the chem i cal proc esses .

— °
C T h r d c i o°
of o i d cl g
4 Z on
. e o f F usi on 9 0 0 1 2 00 ,
e e u t n s x e s i n . u di n
-
Zn O , ,

and d eco m posi ti ons of S i des are completed ; ascendi ng Zn vapor i s oxi di zed
- -

and sulp h uri zed Lead reduced i n the upper par ts of t he furnace tri ckles
.

thro ugh the charge pi c ki ng up Ag on i ts w ,

ay and ac ti ng possi bly upo n lead ,

arsenate and anti m onate; i t joi ns the Pb set free lower down fromPbs PbAs ,

PbSb, and co nti nues to tak e up Ag The sulp hi des of eutec ti c com
,
. posi ti on ,

whi ch softened h i gher up become li qui d and di ssolve other sulphi des to form ,

matte wi th a mel ti ng poi nt lyi ng below that of slag formati on The slag - -
.

co mponents Si 02 FeO and CaO forma slag of lowest form

, ,
ati on tem perature
and thi s t r i ckli ng downward di sso lves the rem
,
ai ni ng Slog FeO CaO as w ell
, , , ,

as o t h er b ases such as Al goa ZnO etc Scorified Pho i s set free and red uc ed by
, , .

C to Pb The thr ee m . ai n produc ts lead m at te and slag set tle i n l ayers , , , ,

accor di ng to th ei r speci fi c gravi ti es ; lead passi ng downward thro ugh sl ag and

matte robs these of some preci ous metal ; matte i n a si mi lar way removes Pb ,

Cu and Ag fro mthe slag ; at the contac t planes of th e prod uc ts i nterch ange of
,

com po nents takes place to a moderate degree wi th a tendency toward collec t

i ng sulphi de i n m att e and m etal i n lead ,
The lead passes ofl through th e lead .

well ; spei ss m atte and slag are tapped i nto th e fore h ear th fromwhi ch slag
, ,
-

,
 S M ELTI NG LE AD ORE S I N TH E BLAS T F UR N A CE

o verflows i nto a waste slag p ot or granulati ng apparatus, and -

p
s ei ss and

m a t te are tapped peri odi cally i nto sui table r ec ei vers

m
.

1 56. Th er al Balance, heat balance of a metallurgi cal General — I he

process has i ts debi t and credi t colum ns as has the b alance sheet of a co m mercial
a cco unt . In the debi t col um n are enter ed the h eat prod uci ng fac tor s : sensi bl e -

h ea t enteri ng the f ur nac e h ea t generated by the co m b usti on of fuel and exother

, ,

mi c reacti ons of the charge; in the credi t column the heat absorbi ng factors ,
-

h eat carri ed 03 i n li q ui d prod uc ts and i n gases and fum es heat ab sorb ed by ,

endo th er m i c reac ti ons of the charge and heat lo st by radi ati on and conduc ti on , .

A st udy of the data gi v es a therm al i nsi gh t i nto the process .

The th erm al b al ance to be cast i s b ased on blast furnace data ki ndly fur

ni shed by Mr Wi lli amAll en Sm . i th Manager of the sm el tery of th e St Jo seph ,

.

Lead Co H erculaneum MO .
, The constr ucti on and m etall urgi cal detai l s of
,
.

t he furnace are gi v en i n Table 53 The basi s of the calc ulati on i s that of 5 000 .
,

kg of charge smel ted wi th 590 kg of coke

. . .

1 57 Rati o nal Analyses

.
— Th ere were ob tai ned ul ti m ate analyses of raw

materi als and products As no rati onal analyses were avai lable these had to .
,

be m ade up by cal c ulati on assi sted by a general knowledge of th e m ineralogi cal

charac ter of the com p o nen t s of th e ch a rg e W h i l e th e r a t i o n al a n a ly se s g i v en .

i n Tabl e 77 are not ab sol utely acc urate i t i s b eli ev ed th at they are app roxi ,

mately correct .

1 58 Di str
. i buti on of Materi als A Calculati on of Wei ghts of Consti tuents of .

the M cue — The m at te f all i s p er c en t of th e -

w e i gh t of t h e ch a rg e T h e . .

wei gh t of matte i s th erefore p e r c en t of 5 000 kg or 6 1 5 kg I t co n ta i n s . . .

( ana ly s i s T abl,
e 53) kg P b kg C u kg F c .kg Z n a n d , .
,
.
,
.
,

kg S . .

Com b i ni ng the four metals wi th the S necessary to gi ve sulphi des gi ves 81 4 , .

kg PbS ; . kg Cuzs; 36 8Zn+ 1 8 1 S . . .

kg ZnS Thi s leav es

. . kg S to be com .

bi ned wi th Fe to form FeS ; or roz rS kg FeS There are ‘

. . .

p res e n t i n th e ma t te kg F e ; d e d u c ti ng gi v e s kg F.e w hi ch .
,

wi th kg 0 furni sh es . kg Fe304 . .

B Assi gnm
. ent of M ateri ats — 1 Si ntered ore kg Thi s contai ns . .
,
.

( )
a P b S kg of wh ,
i ch kg ( see a bov e ) go . es,
i n to th e m a t t e .
,

leavi ng kg PbS Reduci ng thi s to Pb and S gi ves . .

kg Pb going i nto metal and . kg S of whi ch kg go to .

,
.

f urnish the small p ercentage of S i n the metal and kg enters the .

matte a s Fes .

( )
6 Ph SO 4, whi ch resolved gi ves kg Pb going i nto the
kg , . .

metal and 68 08 + 0 enteri ng the gas .

( )
c 2 P bO Si O z kg T h e 1 9 2.0 kg w ast e ,
slag r ep or ted ‘
c a rry . .

p er c en t or kg P b wh i ch c orr es
.
p o nds to kg 2 P b0 Si 0 2 .
,
. . .

Deducti ng thi s am o unt fromthe to tal leaves kg .

The theoreti cal balance sheet of materi als sho w s kg i ncludi ng kg of t e .

,
.

melted slag , or kg . as co mpared wi th th e reported wei ght of kg .

346 ME TALLURG Y OF LE AD

TAB LE 77
—Tns onrmCAL BALAN
-
CE 51 mmo r MAmmLs
'
or m Can oe
0 ; or 5000 K0
m
. .

0111: 590 KG Co
.

'

Charge Products

m
Co p onent s

Si ntered ore kg.

PbS . .

Pb804 .

2 PbO . SlOz

Pyri tes ci nder 1 40 kg .

I ron scale 3 2 kg
.

Refine
ry ski mmi ng s 1 88 kg.

Slag 4 6 7 kg .

4 57 7

Coke 590 kg .

494 4

Ash .

Blast kg
. dry) .
34 8 M E TALLURG Y OF LE AD

( )
b Fe, o,, kg ; red uced gi ves . kg . Fe entering the matte , and

kg . 0 enteri ng the gas .

( ) c Si 02, kg ; enters the slag

. .

( )
d X, k g ; enters the slag
. .

I ro n s a e, c l 3 2 kg .

( ) a Pozog, kg ; red uced . gi ves kg . Fe enteri ng the mat te , and

kg . 0 enteri ng the gas .

k
5 g ;( ) 02 ,
b
e S
n i
t er s t he slag 1 . . .

( ) , 3 g;
c X 0 k e n te r s th e s l ag . . .

6 Refinery ski
. i ng , 1 88 kg mm .

Pho, 1 88 kg ; . reduced gi ves kg . Pb enteri ng the metal , and

kg 0 enteri ng
. the gas .

Slag 4 67 kg , .

a) Sl ag , k g ; e n te rs th e sla g . .

( )
b Pb , 3 3 k g; ent er s t h e eta.l . m .

8 . Coke, 590 kg .

( ) a c a Fi xed
rbo n k g; en t ers th e g a s ,
. .

( )
b V ol a ti l e hydroc a rbo n k g ; en ter s t he gas ,
. .

( )
6 W a t e r k g ; e nt er s the g a s,
. .

( )
d A sh kg; en te rs th e s
,
lag . .

Blast kg , dry) . .

The furnace recei ves p er mi nute 1 36 m of ai r I t smel ts 2 00 metri c tons ’

.

or kg charge i n 2 4 hr or 5000 kg the basi s of the th erm

. al balanc e .
,
.
, ,

i n 36 m in The volum e of ai r p er charg e of 5000 kg i s 36 X 1 36

.
=
4 96 m
8 3
. .

The atm osp h ere co ntai ns about 1 0 gm moi stur e p er m; the 4 896 m blower ’ 3
.

ai r c ontai n kg water The ai r i n the blower roo mi s assumed to be at . .

-

C ; th e 4 896 m m o i st ai r at 2 0 C and normal pressure corr espond to

° ' °
20 . .

m dry a a 0 C these
a
i r t r n a
a i r wei gh = °
kg 44 76 5 kg . . . .

N+ kg 0 Addi ng the water gi ves 581 9 kg

1 59 Cal culati on of Th erm
. . . .

. al Balance for a Charge — In casti ng th e therm al

balance for one charge of kg ore and flux and 590 kg coke gi ven i n Table . .
,

77 , t h er e h as to b e a sc er t a i ned th e i n co m i n g h ea t l i ste d i n T abl e 7 8 un de r ,

D ebi t and the o utgoi ng heat li sted under Cr edi t ; th e col um

,
ns hea d ed Per cent , .

of to tal sho wclearly the relati ons of heat p roducing and h eat consum i ng factors - -
.

The detai ls of the calcula ti ons are as follows :

A Debi t S ide of B al ance S heet
.
—
1 B urni ng C to CO 2 4 30 Cal p er kg C .
,
. .

h i =
T e gas analy si s g ves C02 1 9 and CO 1 0 p er c ent = The to ta l carbo n .

i n the gases i s kg fromthe coke and kg fromthe li me rock Of . . .

=
t hi s ,
1
969 X 53 3 1 8 2 9 kg b urns to CO Thi s l eaves
0 . kg C i n the . . . .

g a s a s C 0 2 of wh i ch 3 ,c a m e fro m th e li m e rock a n d b urn ed to CO : ,

fro mthe coke .

82 X 0 = Cal
1 -
9 2 4 3 4
4 4, 44 7
2 . Burni ng C to C02 , 8 1 00 Cal p er kg C : . .

Cal .
 S MELTI NG LE A D OR E S I N TH E BLAS T FURN ACE

3 B urni.ng Zn to ZnO , 1 3 5
0 Cal p er . kg . Zn : The zinc going i n to the gas
is kg .

Cal .

4 B u r ni
. ng FeO to F e 304, 34 1 Cal p er kg FeO : So e FeO i n th e 2 FeO Si Oz . . m .

o f t he sinter ed ore w as assu ed (p age 34 7) to enter the at te as Fe304 m m .

Cal .

5 For . mati on of FeS fromFe , 4 2 8 Cal p er kg Fe . .

Cal

6 . For mati on of Slag , 1 35 Cal p er kg , app roxi

. . ly : The to tal slag p ro mat e

d uced i s kg There . were ob tained kg from the 2 FeO Si 02 . .

,

a nd from foul slag or ,

kg slagged materi al D educ ti ng thi s
. .

fro mthe to tal gi ves kg slag formed . .

x 1 35 Cal .

7 Sensi ble
. H ea t i n B l ast at 20
°
C . : Thi s i s fo und by the prod uc t of vol ume
X sp ecific hea t X te p erat ure m .

Dry Cal .

There are p r esent kg . H 20 = 60 .

5 m v ap or 3
.

Cal .
, gi vi ng Cal .

Fi g ured r
°
8 Sensi ble H eat i n Charge and Coke at
. 20 C . : as unde 7 g i v es

Cal .

and X =
X 20 6 C l
590 0 .
S74 773 a .

Thi s fini sh es the hea t p roduci ng i tems to be entered i n the D ebi t col um
-
n .

T h ey sho wthat er c nt of th e h eat ner a t ed r esul ts fromth e o xi dati o n

p e ge .

of C .

Credit S ide B alance S heet — of Pb S Pb Red uc ti o n 8 C l

B .
f o to . 1 .
, 9 a .

r kg Pb: kg Pb i n s n ere o e+ 3 3 kg
i t d i n a =
l g 4 1 7 3 kg
p e . . r s . . . .

X 8 = 0 8 6 Cal
4 73 9
1 4 , 9 . .

2 . of PhSO , to Pb 503 and O

Reduc ti o n , , , 59 8 Cal p er kg Pb : . . kg . Pb
i n si nter ed ore+ 1 0 3 kg i n bur nt f ume = . . kg .

1 57 . OX 598 Cal .

3 R e
.d uc ti o n of 2 PbO . Si Oz to Pb, 4 2 5 Cal p er kg Pb . .
( esti mate ,
no figures

av ai labl e) :

Cal .

4 . Reduc ti on of Pho to Pb, Cal p er kg Pb : 245 . . kg . Pb in si ntered

ore+ 0 .
5 kg . m
in b urnt fu e+ 1 74 6 kg i n refinery ski . . mmi ng kg . Pb .

Cal .

5 R ed.uc ti o n of ZnS to Zn , 66 2 Cal p er kg Zn : T he Zn . . ente ri ng the gas as

ZnO i s first red uced fro ZnS m .

X 66 2 Cal .

6 . Reduc ti on of 2 FeO . Si 02 to FeO , 54 Cal p er kg FeO 1 . .

4 6 . 0X 1 5 4 =
7 4
0 8 Cal . for the FeO that goes as Bes04 i n to the matte .
350 ME TALLURG Y OF LE AD

7 R e
.d uc ti o n of 2 FeO Si Og t o F e,
1 37 1 Cal p er kg Fe . . .

The Fe goi ng i n to the at te w i th the S of the PbS and ZnS m mount

a s to
kg.

Cal .

8 . Red uc ti on Pegos to Fe304 , 97 Cal p er kg Fe304

of . .

kg . Peso. i n pyri te ci nder + 2 9 2 kg i n i ron scale = 1 1 3 9 . . . kg . Fe304 .

= Cal
1 13 .
9 X 97 .

9 D e
.co mp o i ti on
s of CaCOa, 806 Cal .
p er kg . Cao
1 59 . 0 X 806 = Cal .

10 . Deco mpo i ti on
s of MgCO. , 733 Cal p er . kg Mgo .

Cal .

1 1 . Red ucti on of ( : 1l to Cu, 1 60 Cal .

p er kg Cu .

The metal carri es p er cent . Cu or 65 . kg Cu . .

X 1 60 = 1 04 0 Cal .

12 . H eat i n metal at 800 °

C ; to tal
. heat of Cal p er kg , . . a pproxi mately
1 73 6 0 X 2 5 . . 1 Cal .

13 . H eat i n matte at 1 2 00 °
C ; to tal . heat of 2 50 Cal p er kg . . pproxi mately
a

X 50
2 = Cal .

14 . H eat i n sal g at 1 2 00
°
C ; total
. heat of 3 5
2 Cal per kg , . . pproxi mately
a

2 24 1 . 8 X 32 5 Cal .

°
1 5 H e
.at i n gas at 2 2 5 C
C b urn to CO, gi vi ng m( ’
stan a d rd condi ti on) wi th a mean spe

cific heat of
C b urn to C03 , gi vi ng m( 3
standa rd condi ti on) wi th a mean
spec ific heat of

contai n
rn
3
ai r mN
wi th a mean speci fic heat of 3

kg H 30 furni sh
. m water vapor wi th a mean speci fic heat of
3

CO Cal .

0
C 3 X 5
2 2 = Cal .

N 6 = 2 4 7, 880 Cal.
3, 5 5 X 3 9 X
0 0 2 2 5 .

H gO vapor Cal .

To tal heat i n gas Cal .

16 . H eat i n cooli ng water

Water p er mi nute 560 kg ; . water per charge 560 X 36 kg .

Te mperature of feed water 31 .

5
°
C of overflow water 5
.
, C ri se i n te . mpera
°
t ure 2 2 C .

2 0, 1 60 X 2 2 X 1 Cal .

17 H ea
.t lo st by r adi ati o n and co nduc ti o n ascer tai ned by di flerence .

Thi s fini shes the heat absorb i ng i te s to be entered i n the Credi t col u n
-
m m .

They s how what large amo unts of heat are carri ed away by the metal products ,
352 M E TALLURC Y OF LE AD

care so as to rai se the temperature gradually as o therwi se the water vapor pass , ,

i ng ofl too qui ckly wi ll op en joi nt s of the m ,

asonry thro ugh whi ch later on t h e

l ead i n the cruci ble wi ll p ercolate .

I t tak es 2 4 hr or m ore to dry and warmthe bri ckwork of the cruci ble
. .

Th ere are vari o us w ay s of doi ng t hi s The followi ng procedure i s sati sfactory . .

The wat er i s t urned i nto t he j ack ets so as to fill themand have a sli gh t overflow;
the dam p er i n t h e do wn ta k e i s p ar tly clo sed th e si d e-
or en d ch argi n g doo rs ,
-

are clo sed wi th furnac es h avi ng a hi gh top or the chargi ng op eni ng on the feed ,
-

floor i s cov er ed w i th an i ron p late i f t he gases are w i th drawn b eneath i t A , .

woo d fire i s made on the bo tt omof the furnace that wi ll not reach half way up th e
cr uci ble If i t i s k ep t goi ng for a fewhours always repleni shi ng the wood ash es
.
, ,

wi ll have collec ted i n the cruci ble These bei ng bad conductors of heat have .
, ,

to be rem oved i n order that the b urni ng wood may be i n contact wi th the bo t
tom W h en th ese are raked out by m
. eans of a hoe fro mthe br east of th e

fur nace a newfire i s ki ndl ed Af ter from3 to 4 hr too m

, any ash es wi ll have
. .

acc um ul ated i n the f ur nace for the heat to h ave the desi red effect and th e ,

cruci ble i s cleaned out agai n Whi le the cr uci ble i s bei ng dri ed and war med th e .
,

lead well i s filled wi th glowi ng charcoal and the basi n i tself covered by a pi ece
-

of sheet i ron so as to adm , i t o nly a li ttle ai r th us preventi ng the charc oal from ,

bei ng b urned q ui ckly Si m i larly the breast of the fur nac e i s closed wi th loosely
.
,

set bri ck s by w hi ch the draugh t i s checked and too q ui ck com

,
busti on of fuel
on t he surface pr ev ented The heati ng i s conti nued for 2 4 hr when the
.

o utsi de of t he cr uci ble wi ll feel war mto the touch Thi s shows that all the .

moi sture i s exp ell ed and that the cruci ble can stand a hi gh heat wi thout en
dangeri ng the bri ck work .

The next step i s gov erned by the m ethod used for filli ng the cr uci ble w i th
lead I t i s essenti al for good work to have a clean cr uci ble enti rely fill ed wi th
.

red hot l ead

-
If fill ed i n par t wi th ch arcoal ashes and sm
. all bi ts of charcoal ,

a d ea d layer wi ll be for m ed b et w een lead and sl ag whi ch soon wi ll harden to a

cr ust and attrac t small ob stacles that would o therwi se be carri ed by th e mat te
and sl ag .

Af ter sup plyi ng the cruci ble wi th th e nec essary l ead the first char ges ‘
,

will co nsi st of an easy smelti ng slag wi th much coke and the fl uxes necessary
-

to slag the cok e ash Ore charges gradually rep lace slag charges and the hi gh
-
.
- -

percentage of f uel i s di mi ni shed unti l finally the normal charge i s reached It .

i s bet ter for a blow i ng i n slag to be gl assy than crystalli ne as i t m

-
el ts m ore ,

readi ly h ence a chi lled sl ag i s preferabl e to one that has cooled slowly The
,
.

slag co nsi sti ng of Si 02 30 Fe0 4 0 CaO 2 0 i s b et ter th an any of the o th er t ypes

, ,

gi ven i n Table 64 .

Th ere are three ways of sup p lyi ng the nec essary lead to the furnace by ,

the l ead m el ti ng m
-
ethod w i th i ts vari ati ons the p latfor m m ethod and th e , ,

l ead chargi ng metho d

-
.

1 62 Lead m
. elti ng M eth od
- — Thi s presupposes that the cruci bl e has been .

bro ught to a red heat before the lead i s i ntroduced I n order to accompl i sh
-
.

1
H ofman ,
General Metallurgy , 1 9 1 8, p .
48 7 .
 S MEL TI NG LE AD OR E S I N TH E BLAS T F URN ACE

t hi s, a wood fire i s ki ndled i n the warm ed cr uci ble and som e charcoal add ed ;

t h e blower i s star ted and m ade to run slowly ; the bags of the t uye res are ti ed
or wound up or the bl ast gates are closed excep ti ng that of a tuyere nearest
‘

, ,

t h e breast whi ch i s connec ted wi t h an i ro n pi pe and the latter i nser ted i nto
, ,

th e cruci bl e fro m the breast The bl ast i s allowed to play on to the charcoal
.

unti l i t i s well ablaze A second layer of charcoal i s added and when f ully
.
,

aglow a thi rd and so on unti l the cr uci ble i s fill ed to the j ackets
, , Thereupo n .

the pi pe i s th en pus hed down deeply i nto the glowi ng coal i n order that the blast
may reach the bottom of the cruci ble Meanwhi le the furnace man works .
-

at i ntervals wi th a rod and a hoe t urns over the coal and m oves i t front to , ,

back and vi ce versa so as to get i t all i nto a perfec t glow When thi s has been
, .

acco m pli shed the pi pe of whi ch often a small part has been b urnt ofl i s wi th
, , ,

drawn and the furnace let alone for an hour or two The pi pe i s agai n i ntro
,
.

duced and the charcoal b urnt down the f um

, ac a m an sti rri ng i t t o bri ng all ,
-

parts i nto contact wi th the blast The ashes are removed and the cruci ble .
,

and lead well thoro ughl y cl eaned

-
Thi s heati ng i s repeated from three to .

fo ur ti mes i n 2 4 hr The outsi de of the cruci ble wi ll then have become too hot
.

to be t ouched wi th the hand .

Up to abo ut 2 0 years ago i t w as c ust om ary to fill the cruci bl e agai n

wi th glowi ng charcoal as o utli ned to feed charcoal fromthe throat to reach ,

abo ut 1 ft above the t uye

. res to add a bed of coke extendi ng to the top of the ,

j ackets to charge lead and coke wi th some slag and the necessary fl uxes and
, ,

to fill the furnace wi th al ter nate layers of half ore ch arge and half sl ag charge - -

usi ng the am o unt of fuel necessary for the full ore charge Then followed -
.
,

uncoveri ng of lead well cl eari ng of tuye -

re holes i nserti on of tuyere pi pes
,
-

,
-

and star ti ng of blower havi ng i t m ak e as few rev oluti o ns as possi bl e and

,

g r ad ua ll y i n cr easi ng i ts spe ed .

Ano ther m ethod very co m mon was to p ut i n the breast close the tuyere
, , ,

openi ngs cover the lead well feed fromthe throat charcoal to the top of the
,
-

j ackets and cover the charcoal wi th a bed of coke abo ut 1 ft thi ck ; then have
, .

a m an de s c end i nto th e furnac e and fill i t i n par t wi th blowi ng i n cha rges con -

si sti ng of lead coke slag and fl uxes and end wi th regular ore charges
, , Wh en ,
-
.

the f urnace had b een t h us filled t he charcoal w as ki ndl ed fro mth e tuye res the
, ,

pi p es were p ut i n p lace and the blower was started and made to run slowly
, .

Bo th m ethods c usto m ary wi th E uropean f urnaces tap p ed at th e bo t t o m

of the cruci ble and adapted to Ameri can furnaces havi ng an Arents si phon
tap ha ve been gi ven up as even wi th good charcoal th ere are li k ely to
, ,

be form ed blowing i n crusts whi ch at best are di fi cul t t o rem

-
ove and fre , ,

q uently remai n i n the cruci ble d uri ng an enti re cam

,

pai gn i nterferi ng wi th the ,

norm al wor ki ng Wi th the perverse tendency of a crust to grow duri ng a

.

campai gn there i s danger of the cruci ble freezi ng up soli d The use of cok e
, .

i nst ead of charcoal o nly m ak es t hi ngs worse .

Thi s led t o the present lead m elti ng m ethod The cruci ble and well -
.
,

heated as shown are cleaned the well i s fill ed wi th glowi ng charcoal and covered
, , ,

a fire i s star ted i n the cruci ble and wh en thi s i s fill ed i n par t wi th glowi ng coals
, , ,

22
354 ME TALL URG Y '
OF LEAD

bars of lead are i ntroduced fromthe breast by sli di ng themi n on a paddle .

As the lead m el ts ch argi ng i s conti nued unti l the cruci ble i s fill ed wi th m
,
olten o

lead ; the fire floati ng on the lead i s kept goi ng by usi ng blast i nterm i ttently .

When the cruci ble has been thus filled the l ast embers and ashes are raked out , ,

eno ugh dry ki ndli ng i s charged fro mthe fro nt and then fro mthe feed floo r -

to reach well above the j ackets and then the breast i s p ut i n On top of , .

thi s co m es a 2 ft bed of coke to whi ch bars of lead are add ed i n order t ha t

-
.
,

thi s com
,
i ng down hot m ay help to heat the lead i n the cruci bl e
,
Then follow .

the usual slag and ore charges The wood i s ki ndl ed t hrough the t uyere
-
.

openi ngs the t uyere p i pes are connec ted the blower i s start ed and a gentle
, , ,

blast m ai ntai ned The feedi ng of bars of l ead fromthe top i s often conti nued
.

unti l the le ad i n the cruci bl e has b eco m e red hot -

.

At som e works h avi ng i n Operati on several bl ast furnaces and a drossi ng

,

kettle lead i s taken fromthe kettle and poured i nto the cruci ble i nstead of
,

bei ng mel ted down i n i t Thus e g wi th a furnace 4 8 by 1 60 i n at tuyeres .

,
. .
, .
,

t her e are charged on top of the li q ui d lead 3 ft dry cedar ki ndli ng a bed of ,
.
,

coke 1 ft deep 6 sl ag charges consi sti ng of 8000 lb slag shell s 800 lb i ron ore
.
,
-
.
-

, .

( F e 6
5 p e r c en t ) a n d 1 000 lb . cok e an d t h en sl ag ore ch a rges m a d e. up o f ,
-

8000 lb ore and 2 000 lb slag wi th 1 3 p er cent coke

. Thes e are run
.
,
. .

for 2 days whereaf ter slag i s om

,
i tted and the f ull ore charge of lb wi th ,
-
.

1 2 p er cent cok e i s fed . Care i s taken that the ki ndli ng i s uni form
. ly i gni ted
wi th oil waste D uri ng the first 2 4 hr the blast pressure i s not allowed to exceed
-
. .
-

2 4 oz p er sq i a ; on th e second day i t i s sli gh tly rai sed and t hi s i nc rease

. . .
,

conti nued unti l at the fifth or si xth day i t has attai ned i ts norm al pressure of

from 38 to 4 2 oz per sq i n When the blast has been star ted the first. . .
,

sl ag appears af ter several ho urs and m atte i s no ti c ed i n the sl ag about 1 8 ,

to 2 4 hr later . .

In ano ther i nstance wi th a furnace 4 2 by 1 9 2 i n at t uy eres there i s charged

, .
,

on to the li q ui d lead dry ki ndli ng to reach w ell above the t uye res Then follo w .
,

3 000 lb cok
. e ( for m i ng a b ed 3 f t de ep ) a n d 4 000 lb sla g ; 3 000 lb co k e a n d . . .

3 000 lb s
. la g w i th fl ux e
s to sl ag c ok e as h ; a n d 82 5 lb cok e 6 000 lb c h ar g e -
.
, .
,

wi th addi ti onal 1 2 00 and 1 500 lb slag fed along the si des The furnace i s fil led . .

wi th the last charge to 4 or 5 ft fromthe throat the ki ndli ng i s i gni ted and .
, ,

enough blast p ut on to show a pressur e of abo ut 2 0 oz p er sq i n In . . .

abo ut 2 hr af ter starti ng t he bl ast the first slag appears at t he t uye

. res , .

When the first m at te i s seen i n the slag the pressure of the blast i s gradually ,

rai sed to 36 oz per sq i n . . .

It m ay be add ed that m any m etall urgi sts add m atte to thei r fir st ore cha rge s -
,

as thi s com s down hot and has a deci ded cl eani ng efl ect since i t takes up
e ,

materi als whi ch the slag may refuse to carry out .

The lead m ethod of starti ng req ui res bri ngi ng the cruci ble to a red heat ;
-

and thi s cal ls for m uch ti m e l abor and f uel ; c are m ust be taken t hat t he k i nd
, ,

li ng placed on the lead shall not i gni te ah ead of ti me ; there i s danger of uneven
di stri buti o n of the charges i n the necessary q ui ck filli ng of the furnace; there i s
li k eli hood of all the ki ndli ng not bei ng com pletely b urnt if i t has been pres sed
356 ME TALLURGY OF LEAD

rem ai n par tly fil led wi th forei gn m atter wh i ch i nterferes wi th regular work

,

and i s very li k ely to cause freez i ng of the cruci ble co ntents Agai n i f th e .
,

planks are completely b urnt par tly charred wood wi ll float on the lead and
,
-

form a nucleus for accreti ons Very few if any furnaces are blown i n a t
.
, ,

present i n the manner d escri bed .

1 64 Lead ch argi ng M eth od In thi s m ethod whi ch ori gi nated at Mapi m

.
- — i
.
, ,

Mexi co bars of lead are p iled i n the cruci ble as shown i n Fi g 32 7; they are
, .

follo wed by wood lead and blowi ng i a , ,

-

charges In the examNe to be gi ven th e

.
,

cruci ble i s 4 6 by 1 62 i n and holds about .

,

lb of p i g lead The cruci ble havi ng

. .
,

been warm ed for 4 8 hr i s cleaned; from .

,

to lb of lead i n 1 00 lb p i gs .
-
.

i s stack ed wi th r i n spaces as shown and -

.
,

reach to fro m3 to 4 i n beneath the tuyere .

level Ki ndli ng and oi l soaked waste are

.
-

placed i n front of th e tuyere openings ; front -

and back of fur nace are clo sed ; cord wood

i s charged from the throat to a dep th of

abo ut 3 ft bei ng i ntroduc ed fro mbo th si des
.

of the furnace i n ord er that i t m ay be di s

tri b uted ev enly ; then follow the blowi ng in -

charges gi ven i n Table 80 The blowi ng i n .

-

Fro 3 2 7 — Lead chargi ng for blowi ng

ch a rg es are follow ed by t h e regular ore

m w m
-
. .

i n blast furnace .
ch arg e s to wh i ch so ,e ra a tte i s added t o

wash out the tuyere regi on; duri ng the first -

2 4 hr an extra b arrow of cok e i s add ed to ev ery fo ur th ch arg e

. .

Wh en the f urnace i s filled the lead well i s covered wi th an i ron plate whi ch i s
,
-

luted and wei gh ted wi th a bar of lead The oil waste and ki ndling at the
, .
-

tuy e re pi pes are i gni ted and allowed to burn for 5 to 1 0 mi n The tuyeres arep ut
-
.

TAB LE 80 — BLO W I N G I N GE AE GEs

.
-
 S M E L TI NG LE AD ORE S I N TH E BLAS T F UR N A CE
'

i n, and the blower i s star ted to gi ve n pressure of oz p er sq i a ; the vol um e . . .

of ai r i s i ncr eased duri ng the next 2 hr to furni sh a blast pressure of from .

-

7 t o 8 o z Th e bo t t o m . of th e l e a d w ell b e co m es seal ed w i t h l ea d i n 1 to 1 % hr -

af ter star ti ng ; the cover i s rem oved and the lead mel ted and kep t li qui d wi th an ,

oil b urner
-
Tw o ho ur s after star ti ng the first slag appear s at the tuye
. res ; thi s ,

i s all owed to ri se to the tuy er es and tapped The tap hole i s worked wi th a .
-

rod to rem ove ashes ; the blast i s allowed to blow through to assi st i n removi ng
th em The blast vol um
. e i s rai sed d uri ng the next 4 to 5 hr to f urni sh a .

pressure of about 1 6 oz If the lea d i n the well has not been li quefied by use of .

an oil b urner the soli d pl ug of lead wi ll m

-

, el t i n abo ut 8 hr af ter p ut ti ng on the .

blast and hot lead will ri se qui ckly i n the well In case the lea d does rem
, ai n .

so li d a red hot steel bar i s dri ven thro ugh the pl ug

,
-
Between the ei gh th and .

tw ent y fo urt h ho ur af ter star ti ng the blast i s rai sed to f urni sh 2 6 oz

-
and , .
,

duri ng the nex t 1 2 hr 36 oz pressure The rate of i ncreasi ng the blas t i s

. . .

governed by the surface of the charge whi ch sho uld rem ai n cool and si nk ,

evenly D uri ng the first 36 hr af ter star ti ng the top of the charge i s kep t
. .
,

fro m4 to 5 ft down fromthe feed floor In 36 to 4 8 hr after star ti ng when the

.
-
. .
,

ex tra coke of the blowi ng i n ch arges has b een b ur nt the blast i s rai sed to f ur ni sh -

4 0 t o 4 2 o z an d a f te r 72 hr t
.h e
,
n or m al 4 8 o z pr essur e . . .

Thi s m ethod i s usually sati sfac tory and i s b ei ng adop ted by m any sm el teri es , .

At M ap i m i w here there i s a spei ss fall of from2 5 to

, p e r c ent blow i ng i a -
. .
,
-

crusts or sows are not formed .

1 65 W ork on the Chargi ng Floor

.
— The work on the chargi ng floor consi sts .

i n assem bling ore flux and fuel ; wei ghi ng the requi red am , ounts ; pr epari ng the
,

charge; and feedi ng i t i nto the furnace .

The older as well as the m ore recent m ethods of assem bli ng ore flux and ,

f uel have been di scussed i n § 1 1 4 ; hand feedi ng has been trea ted i n § 1 09 -
.

1 66 Mechani cal Feedi ng

.
L— The charge com ponents m ade up of p i eces of .
,

ore fl ux and f uel vary m

, , uch i n si ze A coarse charge i s preferr ed to one that
,
.

i s fi ne as the ascent of gases i s m

,
ore uni form; but if too coar se the gases pass , ,

off t oo q ui ck ly and do not prepar e the charg e to the r eq ui red degree A fine .

charge ofiers too m uch ob st r uc ti o n to the upw ard tra vel of the gases ;

these b reak thro ugh at di fl erent p oi nts ( formblow holes) do not gi ve the charge -

the necessary therm al and chem i ca l p reparati on and cause loss by ca rryi ng ,

away d ust and fum e There is also d anger of fines tri ckli ng thro ugh the coarser
.

par ts of the charge and arri vi ng i n a crude state at the smel ti ng zo ne ; th ey will
chi ll the furnace and may even fill the tuyeres Thi s may be ob vi a ted by th e
,
.

Glen fil ter charge w 2

hi ch consi sts i n maki ng the charge large and feedi ng up on
a bed of coke first the coar ser par ts of ore and flux then the finer and l astly , ,

the fines At present when charges are m

. ade up largely of blast ro asted m
, ate

1 D wi ght ,
Tr A I . . . M . E .
,
1 90 2 ,
roo m 380 , .

H ixon, E ng Mi n J . . .
,
1 903, n o w 2 67 , .

m
H of an, Mi n I nd , . . 1 903, x 11 , 2 60 .

Anderson, E ng Mi n J 1 9 1 6, CI , 885
m m 34
. . . .
,

Eng Mi n J , 1 884 ,
. . .
, .
 358 M E TALL URGY OF LE AD ’

ri als the amount of fines to be treated has been reduced to such a degree that
A correc t m
,

th ey do not cause any tro uble i xture of coarse and fine i s th erefore .

d esi red Of the ore one thi rd m

1
. i gh t be i n p i eces fro m5 to 2 i n i n di am
, eter -
.
,

one th i rd fro m2 to 3
-

4 i a an d th e r em ai ni ng t hi rd fro m M i n dow n Fl ux .
,
. .

o ugh t to be about of the same siz e as ore; fo ul slag not larger than 6 in ; .

and cok e o ugh t to be brok en som ewhat As long as the am ount of coke .

fines i s not excessi ve ( see there i s no reason for separati ng t hem

fro mthe r est by forki ng .

Wetti ng a charge while bedding or before feedi ng i nto the furnace i s ad

vantageous w i th an excess of fines over the norm al as i t p revents unm ixi ng ,

when the charge i s bei ng handled .

I t has b een show n i n § 1 09 that i n hand feedi ng a charg e the coarse o ugh t to -

be p laced near the center and the fine near the si d e The coke i s also di s ,
.

tri buted m ore along the center than the si de esp eci ally as b ei ng li gh ter than , ,

the rest of th e charge i t i s li k ely to be p trsh ed toward the w alls in i ts de

, s cent

thro ugh the furnace Guyard advocates chargi ng fuel al ternately toward
2
.

the c enter and si de s to ob tai n an even ascent of gas es ; he b eli eves that feedi ng

of fuel toward the center and charge toward the si d es causes wall accreti ons to ,

formimmedi ately above the j ackets wh ereas al ternate feedi ng of fuel toward ,

center and si des will cause accreti ons to formhi gher up i n the furnace .

A stri c t adherence to the pr i nci ple of placi ng coarse toward the center would
draw the gases too much toward the center and cause premature slaggi ng and ,

overfire and leave the finer charge along the si d es i m

, perfectly prepared What .

is w anted i s that the gas current ascend uni form ly over the whole area of the
sm el ti ng colum n and thi s usually i s the case when the sm ,
ok e p asses off uni

formly and q ui etly fromthe surface of the charge if i t i s cool and sinks ,

regularly and evenly

A m ec hani cal feedi ng apparatus to be successful

ments gi ven as regards distri buti on of charge Omi tting the earli er trials
.

ust fulfill the req ui re ,

.
‘
, m
menti oned i n 51 09 the first mechani eal feed whi ch had any marked success ,

was the so called Pueblo system di scussed in 51 67

- -

,
.

1 67 Pueblo System
.
3—
Thi s w as p ut i nto op erati on at Pueb lo Colo about .
, .
,

1 895 .Though i t i s anci ent h i story as far as present prac ti c e is concerned i t ,

em bodi es featur es of sufli ci ent permanent value to warrant no ti ng some of the

detai ls Fi g 3 2 8 gi ves a ver ti cal longi tudi nal sec ti on thro ugh the incli ned hoi st
. . .

In the center i s the chargi ng p i t w i th ch argi ng car placed crossw i se; to the left
on the gro und floor are the ore b eddi ng b i ns and on the second floor i s the -

sam pli ng b ui ldi ng ; to the ri gh t are the bi ns for fluxes and fuel and adjoini ng
-

, ,

a bat tery of seven blast furnaces 60 by 1 2 0 i n at tuye res wi th a worki ng hei gh t

-

,
.

of 2 0 ft The tuyeres si x on a si de are 4 i n in di am

. eter ; they have Mathewson
, ,
.

water cooled nozz les ( Fi gs 1 86 and 1 87) proj ec ti ng 6 i n i nsi de the jackets th us
-
. .
,

D wight , loc . ci t .

E mmns o ,
“Geolo
gy and Mi ni ng I ndustry of Leadvill e ,
”
U S Geol Surv ,
. . . . Monograph
x1 1 , p . 665 .

D wi ght , Tr A I . . . M . E .
, 1 90 2 , xxxn, 3 75 .
360 M E TALL URG Y OF LE AD

Fro . 2
3 9.
— E nd elevati on .

FI G 330 . .
—Si de elevati on .

FIG 33 1 — Plan
.

ms chargi ng car
. .

Pros
.
3 2 9 to 33 r — W i lli a . .
 SMEL TI NG LEAD ORE S I N TH E BLAS T F URN ACE

wh en taken, coll cted i n V shap ed

are e -
b ins near the track and di sch arged
i nt o a ear running to the sa pli ng mi ll m -
. The rej ec ted materials go i nto the
flux and fuel bi ns .

Fi gs 3 2 9 33 1 gi ve si de and end elevati ons and plan of th e Wi lli am

.
—
s ch arg i ng

car whi ch ho lds abo ut 5 to ns ch arge

,
I t is 5 ft 6 i n by 9 ft 1 % i n . . . . .
,

has ver ti cal si des to a d ep th of 3 ft 3% i n an A shap ed bo t to m and hi nged . .

,
-

di scharge doors to be opened and closed by levers at each end

-
The car i s .

fi ll ed at the ends fro mb ugg i es by wheelers who work i n pai rs E ach wh eeler .

wei ghs i nto hi s b uggy one half charge of a par ti cular co mponent tak es his
-

p la ce in the li ne of wheelers on ei ther si de of the charging p i t and di scharges -

hi s b uggy i nto the Oppo si te end s of the ca r par tners d i schargi ng eq ual q uanti ,

t i es si mul taneously unti l the ch arge i s co m

, plete Coke i s added last to avoi d .

breaki ng .

FI GS 33 2 . and 333 — Secti ons through urnace top

. f -
.

Th e fill ed hauled by
car is rope up the a steel tai l -
i nclined trestl e track -

°
on an angl e of 1 7 to the feed floor and stopp ed at any fur nac e that i s to be
-

fed ; th e gauge of the track i s abo ut the sam e as the leng th of the thro at of a

furnac e The hoi sti ng drums are si tuated wi thi n th e furnace b ui ld i ng at the
.

crest of the i ncli ne; at the farther end of the b ui ldi ng i s a ti gh tener sh eave to -

keep the tai l rop e taut -

.

The charge i n th e car w i ll show tw o co ni cal pi les near the end s wi th ap i ces of
fines under th e letters a and c Fi gs 332 and 333 and coarse p ar ts i n the valley
,
.
, ,

b bet ween the p i les

, Thi s i rregular di stri b uti o n of coarse and fine i s corr ec ted
.

by three A sh ap ed cast i ron deflec tors ex tend ing across the shaft abo ut 1 8 in
- -

,
.

abo ve the stock li ne wh i ch di vi d e the sh af t i nto fo ur r ec tangular areas ; th ey

-

scat ter the co ar se and fine m ater ials as th ese drop fromthe car and m ak e a ,

more uni form mi xture .

When th e car has been spo tted over a furnace the hi nged doors of the ,

furnace are dropped as shown i n Fi gs 33 2 and 333 and the di scharge doors of
,
.
,
-

the car are opened The ch arge falli ng stri k es the A shaped bo tt o mof th e car
.
-

i s thro wn agai nst the w alls wh ereupo n th e deflec tors correc t uneven di stri bu
,
362 ME TALL URG Y OF LE AD

ti on of coarse and least to som

fine, e extent
at I t wi ll be no ti ced t hat this .

arrangem ent nec essi tates a drop of charge of abo ut 1 0 ft ; thi s causes breaki n
g .

of cok e and packi ng of charge co m ponents bo th undesi rable features

-

,
.

At Pueblo th ere w as efi ected a savi ng of 9 cts per ton wi th a dai ly sm el ti ng .

Fro 334 . .
—Si de elevati on .

Fro 336 —
. E nd . elevati on and transfer car .

FI GS —
.
334 to 336. East H elena charge car -
.

capaci ty of 700 tons charge Wi th decrease i n si ze of plant thi s savi ng fal ls Off
.

q ui ckly so that soon the advantage di sappears enti rely

,

1 68 East H elena System

.

.
1—
Thi s method of m ech ani cal feedi ng d eveloped
.

D wight Tr A I M E 1 90 2 xxxn 380

, . . . . .
, , , .
364 ME TALL URGY OF LE AD

coarser parts roll down the i ncli ned surface of the descendi ng charge and
gath er along the center .

In m any i nstanc es thi s separati o n of coarse and fine w as carri ed too far as ,

th e h eat crep t up alo ng the center of the f urnace and the ore along the si des ,

was i nsufi ci ently prepared Thi s was correc ted by W W Nor ton as shown in
. . .

Fi g 339a T h e A sh ap ed . .
-

spr eader i nstead of bei ng a ,

si ngle c asti ng ; Fi g 339 i s m ade .

,

up of several p ar ts sep arat ed by

op en spaces Fi g 339a The , . .

charge on droppi ng from the ,

car i s not d efl ec ted al togeth er ,

toward the walls but one pa rt ,

falls thro ugh the openi ngs be

tw een the ch annel s and l ands

di rec tly i n the c enter Th ere i s .

th us ob tai ned a sati sfac to ry di s

t ri buti on of charge m uch fine ,

wi th so me coarse alo ng th e
si des and m uch coar se w i th ,

so m e fine alo ng the c ent er .

FI G 339
In usi ng a transfer car t h e
. .
-

ch arge has to drop a consi der

abl e di stanc e The hei gh t of .

fall may be red uced to as li t t le

as 2 ft if the transfer car i s .
-

o mi t ted Thi s i s the case wi t h .

th e blast f urnaces of the S t .

Joseph Lead Co at H ercul a .

n e u m Mo The standard ,
.

f urnace i s 4 2 by 1 9 2 i n a t .

t uyeres and 72 by 1 9 2 i n at .

throat has a w orki ng h ei gh t of ,

1 2 ft 4 i n an d fo u r b osh ed . .
,

j ackets on a si de each wi t h ,

three 3 i n t uye res The shaf t -

. .

i s of b ri ck w ork ; the i nner si des

FI G 339 0
. .
are pro tec ted by cast i ro n -

Fm s 339 and 339 0

.
—. D wi ght N orton Sp reader -

plates whi ch extend from the

.

throat to the surface of the ch arge ; f ur ther detai ls are gi ven i n Table 53 The .

th roat of the f urnace Fi g 340 i s covered w

,
i th cast i ron plates re
.
,
s ti ng on -

rollers so that they can be easi ly removed to one si de for barri ng down The .

chargi ng car 1 4 ft 7 i n by 3 ft 7 i n and 4 ft 2 % i n hi gh has hi nged di s

-

,
. . . . . .
,

charge doors whi ch are balanced by wei ghts and mani p ulated by levers I t
-
.

travel s on rai ls car ri ed by I beam s The spreader i s m

-
. ade up of cast i ro n -
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN ACE

an gles wi th i nterveni ng sp aces The center angle as shown i n Fi g 340 has

.
,
.
,

been removed i n order to charge more fine materi al toward the m i ddl e of the
f urnace As the car i s not as long as the throat of the furnace the spread er
.
,

has been shor tened so that i t extends only to wi t hi n 1 8 i n of the ends of the .

f ur nace Wi th thi s change the charge car showed a tendency to b ui ld at the

.
,
-

ba ck ; a deflec ti ng ch ute plac ed to w

°
ar d the fro nt a t an angle of abo ut 60

cor rected thi s evi l i n that more charge i s deli vered to ward the fro nt than t he
ba ck Th e hei gh t through whi ch the charge has to drop the di stance fro m
.
,

bo tt omof car to top of do w nco mer i s 6 ft 3% i n , . .

FI G .
34 0.
— —
Furnace top , St . Josep h Lead Co .
,
H erculaneu m Mo
,
.

Detai ls of the spreader i n use at works of the Uni ted S tates S mel ti ng Co .

at Mi dval e ,
Utah , ‘
are s ho wn
i n Fi g 34 1 preparati on and feedi ng of
. . T he
charges have b een taken up i n § 1 1 4 , and
blast f urnace detai ls i n Table 53 .

The spread er ,
m
susp end ed fro mall spaces between the angl es and
chai ns, has s ,

the cent ral p ar t i s left op en so th at a c onsi d erable p art of t he ch arg e i s deli vered
along the m edi an li ne of th e f urnac e w i thout any di st ri buti on of coarse and fine .

Wi th charges made up largely of blast roasted materi al and the resul ti ng ,

g eater sm
r el ti ng po w er of th e f urnace th er e i s less danger Of the h eat cr eepi ng
,

up i n the f urnace ; thi s has r esul ted i n an endeavor to di stri b ute coarse an d

fine m ore evenly than was for merly the case .

Som e of the fur nac es of the Co nsoli d ated Mi ni n and Sm

g el ti ng Co of Ca n ada .
,

‘
Anderson, E ng M i n J. . .
,
1 9 1 6, cr, 8 85 .
366 ME TALLURGY OF L E AD

Trai l , B C .
how .
,
as s
7 79 h ave op en t ops the gases be g w
n i n Fi gs
i n i th . 1
—
6 1 , ,

drawn fro m the si des The feed openi ng of a furnace i s closed by a plate
.

-
.

runni ng on wheels whi ch travel on the sam —

e t rack as the charge ear The
'

latter arri vi ng i n fro nt of a di nky locomoti ve pushes ahead the plate deli vers
, , ,

i ts charge i n the usual w ay on to the angl e sp reader and p ulls back the p late -

i nto place when i t returns to rec ei ve ano ther charge By keepi ng the feedi ng .

slo t closed the ,

of gases to be treated i n the Cottrell preci pi tator i s
much reduced .

Fro .
34 1 .
— Charge sp reader, M i dvale Utah , .

Thi s rrangement recalls the Freeland chargi ng machi ne i n op erati on at

a ‘

t he copper blast furnac es of D uck town Tenn ,

.

Oth er l ead f urnac es are fed i n a m anner si m i l ar to that i n Operati on at

Nor thpor t Wash (see b elow, ); a t hi r d se t i.s fe d by c ar s wi th si d e wh eels si mila r -

t o those i n use at the blast f urnaces of Grand Forks B C ’

,
. .

T he furnac es of the N orthpor t Sm elti ng and Refini ng Co ; show n i n Fi gs . .

—
1 80 1 83 are hood ed i a
, ; a f u rna c e h a s a bri ck to p fro
. m wh.i ch
, t h e ga ses p a ss

off thro ugh a downco m er i nto a d ust cham ber and the charges are fed from ,

the ends The track s of 30—

. i n gauge on the feed floor enter the furnace at
, .
,
-

one end and ex tend t o the other The charge car i s p ush ed by a di nky locom o .
-

U S Patent, N o 768596, Aug 30, 1 904

. . . . .

Renwi ck, Mi n S c Press, 1 9 1 3 , CVI , 4 4 3

. . .

B rowne, B ull Canad M i n I nsti t , Nove ber, m 1 9 1 6, p 9 76

m
. . . . . .

“ “
H of an, Cop per, 1 9 1 8, p 1 66
”
. .
368 ME TALLURGY OF LE AD

ti ve i nto the furnace and di sch arged consi sts of a 6 by 6 on to a spreader . Thi s
i n angle runni ng along the center Of the f urnace abo ut 1 8 i n belo wthe feed
. .

floor The si de wall s are pro tec ted by 6 by 6 i n angles The charge car show
.
-
n -
. .
-

—
i n Fi gs 34 2 34 8 hol ds 7000 lb charge and cok e
. I t i s 1 4 ft lo ng ; 4 ft . . . .
,

8 in w .i de at th e top 3 ft i n the m i d dl e and narro w s to 2 ft at the di sch arge;

,
.
, .

the dep th i s 3 ft 5 i n The flat bo tt o mi s m. ade of three pai rs of hi ng ed doors

.
,

whi ch close the three co mpart ments Of the car The di scharge doors are .
-

attach ed at th e free ends to i n chai ns w o und severally aro und a longi tudi nal -
.

1 94 i n soli d shaf t enclo sed i n a 2 i n

-
. and thi s i n a 2 % i n pi pe shaf t
,
The -
.
,
-
.
-
.

shaf ti ngs carry at one end 1 0 i n sprock et wh eels co nnec ted by ch ai ns to gears -
.
-

whi ch are severally ro tated by hand through a clutch by a mai n shaft 1 %o ,

i n i n di am
. eter and sq uare at one end The three co m par tments gi ve lati tude .

in m eeti ng the d em ands of a f ur nac e wh en the charges do not si nk evenl y

1 69 Darby Thi m
.

. bl e M eth od —
The detai ls of thi s feedi ng systemat the .

Selby Lead Works and the sm el tery of th e Sulphi de Corpo rati on hav e been

taken up i n 51 09 .

1 70 W ork on th e a . ace fl oor —

Thi s co nsi sts m ai nly i n regula ti ng the -
.

water supp ly taki ng care of the tuyeres and di spo si ng of th e mol ten produc ts
-

, , .

The w
°
ater of the j ack ets i s k ep t at abo ut 70 C the usual test bei ng that .
,

the hand can be q ui ckly passed t hro ugh the outflow i ng water wi tho ut bei ng
scald ed Any i rr eg ulari ty i n the tem
. perature of th e j ackets i ndi cates that the
coati ng on the i nsi de i s th i cker on some than on o th ers and thereby that the ,

sm el ti ng proceed s unevenly ; the slow er d esc ent of the charges on the cold si de

wi ll corroborate thi s on the feed floor -

.

The pressur e of the blast i s w atched and all the ch anges i n the gauge are ,

no ted I t i s r eg ulated by m
. eans of a dam per If the furnace has i ts own .

blower i ts revol uti ons are also counted Self recordi ng p ressure gauges are
,
.
-

used i n m ost plants .

The appea rance of the tuy eres form s a g ood indi ca ti o n of th e i nner condi ti on

of the furnace I t i s not necessary that the enti re month of the tuyere should
.

be bri gh t ; i t i s usually covered by a thi n scale of slag showi ng a star li k e bri ght ,
-

ness i n di fi erent places If the tuy e re b eco m es q ui te d ark 8 bar i s i nserted

.
, .

and the slag p i erc ed to see if i t has gro w n too thi ck In thi s case repeated .

p ok i n g o n ly a ggr av at es m a tter s a s a
“n o se
”
of ch i ll ed sla g w ill for m wh i ch ,

reach es i nto the f urnace ( For correc ti on of th i s evi l see .

Sp ei ss m at te and slag are usuall y tapp ed i nto a set tler ( 51 1 8) fro mwhi ch
, ,

the slag overflows i nto a recei ver to be hauled to the dum p or granulated
and sp ei ss and m atte are di sch arged p eri odi ca lly

The lead i s usually tap p ed fro mthe well ( 51 1 5) into a p ot and cast i nto
bars ; i n the absence of a well i t i s tap ped wi th sp ei ss and matte i nto a shallow ,

basi n fromwhi ch i t i s ladled i nto bars af ter the soli dified cake of spei ss and m
,
atte

has been r em oved .

In tapp ing the slag the f urnace m an used to h ave tw o ln steel bars
,
- -
. ,

6 to 8 ft long and tw o 1 0 lb do uble fac ed sl edges

.
, Wi th the i ncreased size of -
.
-
.

furnaces the clay pl ug whi ch clo ses the tap hole rarely beco m es sufi ci ently -
 S M EL TI NG LE AD ORE S I N TH E BLAS T F UR N A CE

ha rd to b r tw M i n rods 1 2 to 1 6 ft long b ent to a ci rcular

requi re steel a s; o -
.
, .
,

handl e at one end usually serve for thi s p urpo se Wi th a rod of thi s leng th .

t he furnace m an can stand a sufi ci ent di stance fro mthe f urnace i n do i ng hi s

-

work so as no t to be exposed to the fumes ari si ng fromthe tap hole There are -
.

provi ded two stop pi ng rods of i n i ro n and 1 2 to 1 6 ft long w -

i th di sks 2 % i n,
-
. .
, .

i n di am eter for the clay plug and tw o i n i ron rods also 1 2 to 1 6 ft lo ng for ,
-
.
, .
,

ro ddi ng .

In tappi ng i t i s the rul e to k eep som , e slag i n th e fur nace At cer tai n i nter .

vals th e lead and slag are allowed to ri se i n the f urnace until the li ttl e blue flam e ,

seen thro ugh the tuye res i ndi cates that the slag has nearly reached that level , ,

when the furnace i s tapp ed clean to see how much slag the furnace holds If .

t h er e i s less slag than usual i t shows that the t uyere sec ti on i s not as free as i t ,
-

o ugh t to be I t i s advi sable especi ally wi th a long furnace to allow the blast
.
, ,

t o blow on and off out of the tap hole for a whi l e to be sure that all slag has -

been rem oved If thi s i s not done the slag i s li k ely to buil d up around the
.
,

t uy eres especi ally aro und those at th e b ack ; and thi s necessi ta tes later on
,

much roddi ng .

M a tte perhaps so me spei ss and usually a small am

, o unt of lead are tapped ,

fro mthe fore hearth wi th bars of 94 4 msteel fro m6 to 8 ft lo ng ; the tap hole
-

,
.
-

i s clo sed w i th a clay pl ug as i s the slag tap The m atte tap usuall y i s hard and -
.
-

r equi res sledgi ng .

I n or der to m ak e the tappi ng l ess ard uo us the tappi ng bar i s dri ven by a ,
-

few gentle strokes of the ham mer i nto the soft clay plug wi th whi ch the hole -
,

h as b een clo sed unti l i t reaches the hard ened i nteri or , The bar rem ai ns th ere .

unti l t he next tap pi ng when o nly the i nner crust has to be broken , An oxygen .

t o rch to m el t out the m at te i n the tap hole has b een succ essfull y ap pli ed by -

Brow ne and o th er s ; the use of elec tri ci ty for thi s p urpo se has been advocated
‘ z

by T hom pson Hi xon Welsh and Veri tas

3 6
, , .

The lead mthe cruci bl e rs alway s at a lower l evel than mthe well as the ,

p r ess u r e of th e bl ast a nd th e w ei gh t of sl a g a n d ma t t e forc e i t dow n w a rd I t .

i s essenti al that th e lead i n the furnace m ay r i se to the sam e level as the sl ag

ta p ; if i t do es not spei ss and m at te wi ll be too far rem , oved fromthe zone of

f usi on and thus li able to cool and forma crust
, .

The l ess lead th ere i s i n the charge the hi gher m ust be h eld i ts level i n the ,

cruci ble that i t may not cool as i t i s not freq uently replaced by fresh lead that ,

has j ust p assed thro ugh the ho t test par t of the furnac e Form erly the top s of .

the cr uci ble and th e wells were on the sam e level ; at present the w ell i s b ui lt

up to extend fro m8 to 1 0 i n above the slag tap

'
I -
. .

The lead used to be taken fro mth e well by di ppi ng and cast i nto bars ( 51
Tr Canad
. . Mi n . I ns t , . 1 91 5 , xv m9 , 1 .

McGill N ev , .
,
E ng . Mi n . J .
, 1 91 7, CW , 704 .

E ng M i n J
. . .
, 191 6, CI , 69 8 .

4 Op . ci t .
, p 608
. .

Op . ci t .
, p .
95 1 .

Op . ci t
6, err, 5 1 7
.
, 1 9 1 .

7 von Schi pp enbach, Mctall u Era , . . 1 9 1 4 , xx, 652 .

2C
370 M E TALL URGY OF LE AD

In doi ng thi s there i s dan ger of removi ng too much at a ti me; fur ther the bars
, .
,

are sure to contai n m uch dro ss wh i ch c ollec ts larg ely on the surface of a bar ,

but i s also i rregularly dissem i nated thro ugh i t As th e dro ss runs lower i n Ag .

than the clean l ead m uch di ffi c ul ty i s enco unter ed i n sam

, pli ng and later
i n assayi ng At present the lead i s always tapped at i ntervals fromth e well
.

i nto a collec ti ng p ot so m eti m es heated fro ma fireplace; the dross i s ski m

, med
and r et urned to the blast f ur nac e and the clean l ead m olded Wi th furnaces ,
.

runni ng charges hi gh i n lead the collec ti ng p ot i s hauled to a drossi ng kettle ,

-

and em p ti ed or the lead i s run fromthe well i nto a casti ng machi ne and the
, .
,

bars are then melted i n a drossi ng kettle -

.

In tap p i ng froma f urnace abo ut 1 000 lb of lead the ch arge wi ll si nk sud .

,

denly to occ upy the space set free by the l ead Th i s m ay resul t i n parti cles of .

unm el ted charge passi ng too q ui ckly fromthe sm el ti ng zo ne to be f used and ,

form i ng the nucleus of a crust For thi s reaso n som e f urnac e m en p r efer di ppi ng
.
-

to tap pi ng esp eci ally wi th low l ea d charges ; the am

, ount to be di pped is then -

regulated by the numb er of charges that are fed i nto the furnace and the per ,

centage of lead they contai n .

The clean bars of b last furnace lead are m ark ed wi th a runni ng lot num ber; -

removed fromthe mold wi th a pi ck or o therwi se ; pi l ed to be sampled if this ,

has not b een done d ur i ng the m oldi ng ; wei ghed ; and shi pped .

A furnace i s i n good work i ng ord er b elow when the tem perature of the ,

j ackets i s uni formly hi gh the pressure of the blast does no t fl uc tuate and , ,

the t uy e res remain bri ght havi ng o nly shor t no ses The furnace wi thi n a ,
.
,

gi ven ti me sho uld produce the same amo unt of slag ; the tap hole should be
,
-

nei ther too hard nor too sof t ; and the l ead i n the well sho uld be of a bright

red color play wi th the bl ast and si nk sl i gh tly every ti m

, e t hat slag i s tapped ,
.

On the furnace floor are req ui red for every f urnace one furnace keeper one ,
-

tapper who look s af ter the lead and one helper to gi ve the slag m atte and , ,

lead pots a clay wash and to do o th er work

-

W ork on the Dum

.
,

1 71 .
p
— In for m e r ti mes wh en l i t tl e m a tt e w as m a
. d e an d ,

the furnaces were sm all th ere w as i n use the ord i nary tw ,

o wheel slag po t Fi gs - -

,
.

2 34 and 2 35 I t i s at pr esent used as an auxi l i ary p ot i n ore sm elti ng and -

especi ally i n the sm el ti ng of i nter m edi ar y pro du c ts i n a r efi ne ry T h e po t is .

wheeled out on the d ump and i ts contents are allo wed to cool ‘
,
Wh en thes e .

have soli di fied the p ot i s ti l ted and the cone of slag wi th sp ei ss and m
,
atte , ,

adher i ng to the bo ttom roll ed out I t i s brok en wi th a sl edge sp ei ss and

, .
,

matte are sor ted and pi led and slag thrown over the dump or reserved for ,

further treatment .

At present wi th large furnac es m

,
ak i ng m uch m atte the fore h earth or set ,
-

tli ng reverberatory fur nace collec ts any overflow i ng lead w i th the spei ss and
matte The waste slag p ot whi ch catches the overflowi ng slag i s hauled by
m
-
.
, ,

horse mule steam or elec tri c power to the edge of the d ump and em i edf -

i n som e i nsta nc es the waste slag i s granul ated .

Keller Tr A I M E ,
, . . . . . 1 89 3, xxrr, 5 76 .

Austi n, Tr A I M E . . . . .
, 1 896 , xx vr, 40 1 .
372 M E TALLURGY OF LE AD

fl uxes on the q ui ckly descendi ng one; then a full streamof water i s t urned into
the hot j ack ets and that of the cool j ackets r ed uced ti ll there i s j ust an overflow .

By the co m bi nati on of these rem edi es the sm el ti ng of th e fur nac e on one si de

more than the o ther wi ll be correc ted and the charges wi ll ri gh t themselves ,

agai n af t er a fewho ur s Shaki ng up the charge wi th a long heavy ( rlé ia )

.
,
-
.

steel bar i ntrod uced thro ugh th e f eed door i nto the hangi ng si de wi ll often
,
-

hasten matters At so me works that have to trea t ores ri ch i n zi nc i t i s the

.
,

prac ti ce at the begi nni ng of ea ch day sh i ft to dri ve i n a steel bar at the four -

corners of the f urnace as far as the top of the j ackets thus looseni ng any wall ,

accreti ons that are form i ng By doi ng thi s the num ber of ti mes a furnace .
,

has to be barr ed down to rem ove accreti ons i s greatly red uced and the whole ,

r unni ng i mp roved .

When the charges descend i rregularly i t of ten h ap pens that the fire creeps ,

up and the ch arge b eco m

, es ho t on t he surface ( overfi re fire top hot top) ,
-

,
.

FI GS .
4
3 9 to 35 2 — . W all accreti ons i n blas t furnace .

The f urnace may then be fed down whi ch con i ts i n addi ng only j u t enough , s s s

fre h charge to keep the flame or heavy smoke frompassing thro ugh Wh n the
s . e

su rface has th us been lowered for 2 or 3 ft the furnace i s fill ed up q ui ckly agai n .
,

and th e top th us coo led Si m ple spr i nkli ng of water on the top of the charge
.

has only a tem porary cfi ect Thi s feedi ng down helps mat ters if the overfire .

does not co m e fro ma cr ust in th e cr uc ible .

The cause of the i rreg ular descent of the charges li es generally i n the form a

ti on of wall accr eti ons ( 5

-
whi ch begi n on top of the j ackets and grow thi cker
They assum e di fi erent for m — l
towar d th e f eed door -
. s Fi gs 34 9 352 by Ile s . .
, ,

sh ow so m e ex t rem es Fi g 34 9 represents a m
. ore or less regula r shape and the
.
,

sm el ti ng p ow er of the furnace i s no t nec essari ly r ed uced Wi th i rr egular hang .

i ngs li k e tho se i n Fi gs 350 3 51 and 352 the d escent of the charge

,
. s wi ll be great ly
, , ,

obstr uc ted and the amo unt of flue dust much i ncreased The charge wi ll be
,
-
.

t i gh t at the narrow p ar ts of the f urnace and the blast enteri ng the t uye res wi ll ,

be co nc entrated i n a fewplac es and cause blow holes

”
As soon as th ese wall -
.

accr eti ons are di scovered they h ave to be cut or b arred down , In ord er to .

‘
E ng. Min . J .
,
1 886, xu , 9 3 .
 S MEL TI NG LEAD ORE S I N THE BLAS T F URN A CE

reach the lowest part the furnace i s fed down and the blast lessened at the
,

sam e ti m e ti ll the charge has r eached abo ut the top of the j ack ets
, Whi le i t .

i s bei ng lowered no lead i s rem ,

oved fromthe well i n order that the cruci ble ,

may be enti rely full whi le the barri ng out is going on The blast i s stopped the -
.
,

b last pi pes are removed and the tuyere openi ngs clo sed or the gates sh ut ; all the
- -

slag i n the f urnac e i s tapp ed and the flow of water i nto th e j ack ets nea rly sh ut O E
, .

W hen everythi ng i s ready 8 charge of coke i s gi ven wi th som ,

. e slag and flux form ,

i ng a bed for the accreti ons to fall on as they are chi pped fromthe walls The .

c utti ng out i s best b egun j ust above the j ack ets A square poi nted steel bar
-
.
-

abo ut 1 % i n i n diam eter and long eno ugh ( about 1 8 ft ) to reach fromthe top
. .

of th e j ack et well i nto the Opposi te si de on the feed floor i s dri ven wi th a -

sl edge i nto the cr ust above the j ack et If i t does not yi eld a rope ti ed aro und .
, ,

t he head of the bar i s thrown to the Opposi te si de where several m

, en p ull i t ,

and th us break Ofl th e cr ust Thi s i s repea ted unti l the crust has been rem
. oved
i n a num ber of layers two sets of men worki ng on Opposi te si des Whi le the
, .

crust i s bei ng barred OE fuel slag and fluxes are added that i t may be smelted
, , ,

out wh en the furnace i s star ted up agai n

, The reas on that the barring down i s .

begun fro mbelow i s that o therwi se the broken crusts and small slag cha rges -

t ha t h ave b een added m i gh t so fill up the f urna ce that i t wo uld be i m p o ss i bl e to

r ea ch the crust at the top of the j ackets and newaccreti ons wo uld formagai n ,

qui ckl y Someti mes however i f the crust i s thi ck and hard the barri ng down
.
, , ,

i s begun fro mthe top co nti nui ng until the acc um ,

ulated crus t and slag charge -

meet the clean si de wall when these are smelted out keep i ng the charges low
-

, , .

T h e furnace i s nowlet do w n agai n and th e seco nd half of the barri ng do w , n is -

begun at the top of the j ack ets and co nti nued up w ard .

When the si d es of the f urnace have been cleared the tuyeres are cl eaned out , ,

t h e t u é re—p i p e s i n s er t ed or t h e g at e s a re op e ne d a w ea k bl a st to be i ncr ea se d
y , , ,

grad ually i s turned on and smel ting resumed Care must be taken abo ut th e
, , .

wa ter supply as the j ackets grow hot q ui ckly and abo ut the tap p i ng of the ,

slag as th e wall accreti o ns of ten m

,
-
el t v ery fast and th ere i s danger of th e slag ,

ent eri ng the tuye res Af ter starti ng the furnace i t i s so meti mes fo und that a
.
,

sm all c rust has form ed ov er the lead whi le the blast w as sh ut off Thi s i s .

p e rf o ra ted w i t h a lo n g i ro n rod or w i th a st eel b a r i f n e c ess a ry and wi l l soo n , ,

di sapp ear i f the f urnace w

, as i n good worki ng ord er b elo w befor e the c utt i ng

o ut began .

A second m ethod of barri ng do w n a f urnac e sai d to work w ell i s to let , ,

dow n the cha rge to below the upp er ri mof the j ackets and gi ve a bed of cok e ,

a s previ o usly desc ri bed I n t he m eanti m . e t he bri ck s bet ween the j ackets and ,

th e coll ar on whi ch the shaf t rests are rem

,
oved for a di stance of 1 or 1 % ft
,
.

T h e accreti ons are cut down begi nni ng fro mabove and raked out thro ugh , ,

t hi s op eni ng When t he shaf t i s clean the openi ng i s bri cked up l i gh t charges

.
, ,

are gi ven the f urnac e i s fill ed up wi th ore charge and the blast let on
, The -

, .

acc reti o ns go to the roasti ng fur nac es .

A t hi rd m et hod of bar ri ng down i s dangero us al tho ugh i t m ay be nec essary ,

at ti m es and i s even excl usi vely used by so m e m etall urgi sts The charge i s let .
374 ME TALLURGY OF LE AD

down to the top of the j ackets and cutti ng out begun fromthe top and conti nued ,

unti l the crust coll ecti ng i n the f urnace has ri sen so hi gh that the work canno t p ro
ceed any f ur ther The tw o breast j ack ets are nowtaken down and the contents
.
-

of the furnace raked out i n order that the c utti ng may co nti nue unti l the walls
,

are cl ean Thi s m

. ay tak e as m uch as 1 8 hr Tw o parti es of t hree m en each .
,

worki ng on opposi te si des of the furnace do the c utti ng one man holdi ng the , ,

bar and tw o sl edgi ng As the work i s hard and has to be done as q ui ckly as
.

possi ble the regular hands have the constant assi stance of furnace men and
,
-

help ers fro m o ther furnaces who work half an ho ur at a ti me Whi le the , .

accreti ons are bei ng rem oved a crust 6 i n thi ck or less wi ll formon top of the
,
.

lead . Thi s i s broken up the breast j ackets are p ut back and the lower front
,
-

i s closed Fuel i s fed fromabove to the top of the j ackets and t he furnace
.

blown i n anew addi ng bars of lead to the first slag charges to heat up the lead
,
-

i n the cr uci ble .

Guyard suggests that by usi ng causti c li m

‘
e i n the charge i nstead of li m e

st one th ese accreti o ns m i ght be m ad e less tro ublesom e as li m e has a decom ,

posi ng ac ti on on the sulphi des of whi ch they co nsi st i n great par t The use of , .

burned li me as a basi c flux has already been co mmented upo n As to i ts

desulphuri zi ng acti on i t sho uld be remembered tha t whi le accreti ons next to the
furnace wall s consi st mostly of sulphi des they are usually covered by a thi n ,

crust as hard as fli nt ; thi s i s foll owed by a softer substance that i s often a powder ,

and t hi s agai n cov ered by a cr ust so to ugh that i t i s so m eti m es ext rem ely difli cult

for a steel bar dri ven hard wi th a sledge to prod uce any effec t on i t I t does
, , .

not seem p robable t herefore t hat ca usti c li m ,

e wo uld have any i m , portant
cfi ect on t hese com po si te crusts whi ch must di ffer fro msulphi des as much i n ,

thei r chem i cal proper ti es as they do i n thei r phy si cal .

So m e f urnac e m en have fo und t hat ch argi ng a sm all am o unt of sal t cake

2 -

al ong the Si des of the furnace frequently rem oved hangi ngs .

I t often hap pens even when a furnace i s o ther w ,

i se doi ng w ell that the tap ,

hole beco mes hard and the tuyeres dark The fuel i s then di stri b uted moreover .

the cold places ad di ti onal f uel bei ng gi ven for a shor t ti m

, e i f nec essary One or .

tw o bars Of lead are so m eti m es pl ac ed on top of the charge over the tap or

the t uyeres but thi s ca nnot be co m

,
mended although i t i s often efiectual The , .

change i n feedi ng the fuel w i ll generall y soft en the tap To soft en a crust i n .

front of a t uyere the bag or the gate sho uld be closed or nearly closed as the
, , ,

blast playi ng on chi lled slag can have only a bad effec t If i t i s turned 05 the .
,

heat generated at the nei ghbori ng t uyeres wi ll melt OR the crust ; then a li ttle
blast i s allowed to pass t hrough the t uyere and graduall y i ncreased unti l the ,

full blast ca n be turned on agai n .

Wh en fine ore forms a larger part of the charge m ore co m mo n formerly ,

t han i s the case at present a t uye re frequently beco mes blocked Placi ng an
,
.

”
Open tube t hro ugh thi s and thereby cond uc ti ng the bl ast safel y t hro ugh the

E mmon s, Geology and Mi ni ng I ndust ry of Leadville, pp 7 2

. 8, 74 7 .

E ng . Mi n . J .
, 1 90 5, l x xx , 93 2 .

Lang, E ng Mi n J . . .
, 1 890, x ux , 1 74 .
376 ME TALLURGY '
OF LEAD

i nserted i nt o the hole the crust pri ed up and the broken pi eces raked out
, ,
.

If the crust wi ll not yi eld the hole i s enl arged and the furnace start ed up agai n
,
.

The lead previ o usly bai led out i s returned and i f nec essary fresh hot lea d , , ,

added t he cl ay ball s are rem

,
oved the hollow space i n front is filled wi th fuel , ,

the steel bars are wi thdrawn fromthe t uyere s the breast i s p ut i n the t uye re , ,

holes are opened the pi pes i nserted and the blas t i s let on but very gentl y
, , ,

at first When the first two or three pots of slag have been tapped the rod i s
.

repeatedl y i nserted to keep the hole open until the new slag com s dow
e n .

The lead will soon show the efi ect of havi ng com muni cati on between i t and
the slag partly restored ; i t b egi ns to play w i th the bl ast and becom es hott er ,

thus assi sti ng the work of the newcharge .

A crust i s so m eti m es caused by a leaki ng j acket Thi s i s first i ndi cated by .

the app ea ranc e of m oi sture at the tuyere or the bo ttomof the j acket The leak .
,

i f sm all can be tem

,
porari ly stopped by mi xi ng cornm eal wi th hot water pressi ng ,

it w i t h the hand i nto sm all balls and throwi ng t hese i nto th e water feed er ,
-

of the j acket Soon however the j acket wi ll have to be removed For thi s
.
, ,
.

purpose the crust on the i nsi de i s first allowed to growthi ck by cooli ng whi ch ,

i s done by t urni ng i n a full st reamof w ater and openi ng t he di scharge at t h e ,

botto m Two co urses of bri ck are chi seled out above the j ack et When coo l
. .
,

the furnac e i s stopped the cooli ng water on the si de of th e i nj ured j ack et

,
-

sh ut 06 the water tro ugh r em

, oved and the i nj ured j acket unhi nged taken out
-

, , ,

and a newone p ut i n i ts pl ace The w hole procedure need not take more tha n
.

20 m in Should the crust on the i nsi de of the j acket prove too thi n and brea k
.

out the op eni ng i s cl osed by the i nt rod uc ti o n of clay ball s

, The space where .

the newj ack et i s to be i nser ted m ust be absolutely clean as any li ttle pi eces ,

of bri ck or o ther hard m atter wi ll ob st ruc t the placi ng of the newj ack et and

ca use much delay Of course the foregoi ng has no reference to a furnace w

. i th
wro ught i ron j ackets extendi ng i ts enti re length
-
.

The cl oggi ng up Of the l ead well i s yet to be consi dered In Sm

-
el ti ng sul .

p hi d e ores ri ch i n l ea d su lph i de of lea d h e

,
ld i n sol uti on i n t he cr uc i b l e oft e n
separates wh en the lead asc ends th e channel t oward the basi n A bent i ron .

rod may be i nserted to cl ean i t out Thi s presence of sulphi des i s generall y .

caused by an i nco mplete decomp osi ti on of galena i n the furnac e on account

of lack of heat i n the sm el ti ng zone If the charge i s ri ch i n copper thi s causes
.
,

Coppery lead grad ually to clo se up the channel .

1 73 Blow . i ng out — If ore flux or fuel gi ves out or if the furnace needs t o
-
.
, , ,

be repai red or i f an acci dent happens that cannot be rem

, edi ed i n a short ti m e ,

say i n 1 8 or even 2 4 h r the f urnac e has to be blown out

.
,
Thi s i s done by .

stoppi ng the ore ch arg es and sub sti t uti ng slag ch arges unti l m
-
ost of the ore -

has b een sm el ted out The charge i s allo w

. ed to si nk and th e bl ast i s grad uall y ,

lowered Soon vol umes Of dark smoke mi xed wi th whi te lead fumes wi ll appear
.
-
.

When the charge has receded somewhat and before a flame makes i ts appear ,

ance the dam

, per i n the flue leadi ng to t he d ust chamber i s closed and the fumes -

are conduc t ed i nt o t he ai r by openi ng the dam per on the top of the furnace or
by loweri ng t he sheet i ron stack or by whatever contri vance m
-
ay be i n use
,
 SM ELTI NG LE AD OR E S I N TH E BLAS T F URN A CE

for the purpose If thi s were not done an explosi on mi gh t occur i n the d ust
.
,

ch amber To check the flame and to reduce the temperat ure water i s of ten
.
,

spri nkl ed over the charge altho ugh i ts efi ect on the li ni ng of the f urnac e canno t
,

but be d eleteri o us When the ch arge has sunk as far as the top of the j ackets
.
,

t h e blast i s stopped and the tuy e re pi pes are removed All the li qui d slag i s -
.

tapped the tappi ng j ack et rem

,
oved and the breast of th e furnace i s knocked i n
-

,
.

So m eti m es the f urnace i s blown down al lowi ng t he charge to si nk ti ll o nly ,

h eavy f umes but no flames appea r and the enti re contents are then drawn In
, ,
.

t hi s case th ere i s no need of closi ng the dam per to the dust cham ber ; i n fac t -

many furnaces have no damper at all .

The b ulk of th e slag rem ai ni ng i n the furnace i s w i thdraw n wi th a hoe i nto

i ron wh eelb arrows em p ti ed on the dump and then chi lled w
,
i th water As ,
.

i t is i m p or ta n t th at th e r e sh o u l d b e li t t le de l ay i n draw i ng th e ch arg e a ,

num ber of wheelbarrows are placed one behi nd the o ther near the front of the
furnace As soon as the first i s filled wi th red hot charge i t i s wheeled away
.
-

and r eplaced by th e seco nd the em p ti ed wheelbarro wbei ng p ut at the end of the

,

li ne When all the charge that can be easi ly reached wi th the hoe has been
.

draw n the front j ack ets are taken down and the rest i s rem
, oved Meanwhi le ,
.

a t hi n crust wi ll have form ed on t op of the lead i n the cruci ble Thi s i s easi ly .

brok en and the lead i s then ladled i nto the molds that have been moved
, ,

fro mthe lead well to the front of the furnace

-
.

Blo w i ng down i s m ore expensi ve th an i s generally beli eved The i tems to .

be consi dered are : f uel r em ai ni ng i n the f urnac e loss of h alf a shi f t i n blo w i ng ,

out d i ppi ng the b ulli on barri ng out sam

,
pli ng prod uc ts treatment of barri ngs
, , , ,

work of m ason and extra fire bri ck and fire clay warm i ng the cruci bl e fuel for
- -

, ,

blowi ng i n and loss of h alf a shi ft i n blowi ng i n Besi de the general over
-

,
.
,

hea d expense of the works goes on i n the same way whether all the furnaces ,

are worki ng or only par t of th em I f a f urnac e h as been b low n down and i s .

li kely to be blown i n agai n i n a short ti me i t i s advi sable to keep the cruci ble ,

warm and a pole 2 0 or more feet long i s i nserted fro mthe breast and kept
, , ,

b urni ng slowly .

‘ —
1 74 Furnace and Assay book s
. A dai ly record i s kep t of the work done
-
.

by ea ch f urnace One of the many sui table skeletons for thi s p urpose i s gi ven i n
.

Table 82 The ti m. e when any ch ang e i s m ade i n the ch arge or when any th i ng ,

out of the regul ar occ urs i s no ted i n the fir st col um Rem

”
,
n of ark s The .

second col um n of Rem ark s refers to the di sposal of produc ts especi ally ,

the shi p m ent of l ead b ulli on .

Th e assay record gi ven i n Table 83 furni sh es i nfor m

-

,
ati on about the dai ly ,

assays m ad e of slag m at te and lead b ulli on ,

Under the head of Rem ark s .

are no ted the nam es of any o ther f urnace prod uc ts whi ch m ay be assayed now -

and t hen Tables 82 and 83 represent very si m

. ple forms for keepi ng records of
the m etall ur gi cal work the f urnac es are doi ng In a plant there are k ep t .

si m i lar records for each di vi si on Of work The keepi ng of accounts Of a sm el t ery .

li es b eyond the sc ope of thi s book .

Argall, Mi n S c . . Press, 1 906, 1 m

m 573
, , 7 ,
2 2 750 .
378 ME TALL URC Y OF LE AD
380 M E TALLURGY OF LE AD

Co mposi ti ons of oft lead have been gi ven i n Table 3 ; analyses of lead b ulli on
s

are r ecorded i n Table 84 T he lead content of the latter i s usually 9 7 to 98 per

.
-

cent ; i t often falls to 9 5 p er cent and m

. ay r each even 90 .
p,er c en t w i t h or es .

r unni ng hi gh i n Sb The number of the o ther elements fo und i n blast furnace

.

lead i s large As regards thei r di st ri b uti on i n soli d lead they may be consi dered
.
,

to fall i nto fo ur classes for m i ng soli d sol uti o ns eutecti c m

, i xtures ch em i cal , ,

co mpo unds and havi ng no affini ty whatever for lead The first o ugh t to be
, .

unifor m ly di st ri b uted thro ugh a bar; the second concentrated tow ard the
‘

center whi ch i s supposed to soli dify last ; the posi ti on of the thi rd wi ll vary wi th
,

the solubi li ty ; and the fo ur th w i ll collec t near or on the top B ut som e m etals .

form bo th soli d sol uti ons and eutecti c mi x tures ( Bi ) ; others eutec ti cs and
chem i cal co m p o u nd s ( );
T e a g ai n the e ut ec ti c po i n t s li e so n ea r t o p u r e le ad
t hat the lat ter retai ns a sm all am ount of the forei gn el ement ( Cu) ; las tly
the for ei gn elem ents m ay com bi ne wi th one ano ther i ndependently of lead
and th us add newcom pli cati ons Thi s i rregul ar di stri buti on of so me forei gn
.

el em ents i s bro ugh t out by th e analyses of sof t lead by Streng and of lead
’

b ulli on by Schertel gi ven i n Table 85 Schertel kep t the lead bulli on for 2 4
3
.

T AB LE 85 .
— D 1 5 T111B U T1 0N or ME TALS AN D SU LPH U R IN LE AD
Soft lead ( Streng)

hr . bove the mel ti ng poi nt i n an i ron cyli nder 3 ft 3 i n hi gh before taki ng

a -

,
. .
,

hi s sam ples The resul ts Of Streng show that together Cu Sb Fe Zn and Ni

.
, , , , ,

have a tendency to ri se to the surface; those of Schertel i ndi cate the sam e wi th

t he exc ep ti on Of Sb whi ch he fo und to be conc entrated at th e bo tt o m Prac .

ti cal experi enc e has taugh t that i n a bar of lead the i m puri ti es wi t h the ex , ,

cep ti on of Ag and Au are fo und to have coll ec ted nearer the top t han t he bot
,

t om whi le the reverse i s the case wi th Ag and Au

, The resul ts by the w ri ter .
,

g i ven i n T abl e 86 and Fi g s —

3 57 359 show t h at t he low
. er p ar t of a ba r i s ri
,
ch er
than t he upper and that the c enter of the upper part represents the poore
,
st

Rosenlecher, Berg H ttttenrn Z , 1 89 4,

. . . L111 , 333 , 34 1 .

‘
B erg H itttenrn Z , 1 859 , xv , 1 4 m
m
. . . .

Wagner J ahresb , 1 887, xxx , 401

. .
 SMEL TI NG LE AD OR E S I N TH E BLAS T F URN A CE

TAB LE 86.
— DrST mUT10N or AO or LEAD B ULLI ON

( ) L ( ) a 1 50 -
5 1 48 7 -

Fi g 35 7
- 1 37 0 -
(8 1 49 0
- 1 49 0 -

Fi g 3 58
.

part Si m
. i lar resul ts have been ob tai ned by Pi quet Rah t Roberts and ,
‘
,
2 3

ot hers Raht has sho wn that the p art of a bar whi ch soli difies last i s the
.

p oor es t i n A g The bar r epr esent ed i

. n sec ti o n i n Fi g 360 w as spr ay ed wi t h .

water as soon as molded t hat i n Fi g 361 cast fromthe same b ulli on and at the ,
.
,

0 6 0

S ECT IO N 4 5

C D -

FI GS .
35 7 t o 359 .
— D istri buti on of si lver i n lead bullion .

same ti me was allowed to cool i n the usual way

, . In Fi g 360 the shell , coole
. d
by mold and spray water i the ri chest ; i n Fi g 361 -

,
s . the par ts i n cont ac t wi th t he
heat wi thdrawi ng i ron are the ri chest
-
.

An at tem p t h as b een m ad e t o expl ai n‘

t hi s co nc ent r ati o n of t he Ag i n t he

lower part of t he bar by the sep arati on of the argenti ferous lead whi le cooli ng , ,

A m , 02 8 si l ver p er ton Aver-co O Z B si l ver p er ton

FI GS and — Secti ons thro u h bars of lead bulli on

.
360 36 1 .
g .

i ntocrystals low i n Ag and li q ui d lead hi gh i n Ag It i s sai d that when a bar .

has been m olded the surface cools first and crystals begi n to formthere; that
, ,

the si des then slo wly soli di fy a mass of li qui d lead and crystals remai ni ng i n ,

the c enter AS the cooli ng i s supposed to proceed fro m the top downwar d
.

Ros wag, Désargentati on du plo b, m Dunod ”

,
Pari s, 1 884 , p . 1 2 7.

Mi n I nd 1 89 4 , III , 4 1 4

m m4
. .
, .

Tr A I
. . . M . E .
, 1 89 8, ,
13 .

Roswag, loc . ci t .
, p . 1 26 .
382 ME TALLURG Y OF LE AD

th e crystals wi ll conti nue to formon the cooler upper si de and gradually force
the ri cher li qui d lead toward the bo ttom Thi s t heory presupposes t hat t h e .

mold i s a poorer conductor of heat than the ai r whi ch can not be the case Th e , .

reas o n that the surface of a bar i s so much poorer than the other parts i s no t
only because of the uneven cooli ng but also on account Of the i m p uri ti es t h at ,

ri se to the surface They run much lower i n si lver than the pure lead as i s
.
,

sho w n i n Tabl e

T AB LE 87 .
— W E I GH TS AN D SI LVE R -
AS S AY S or LE AD B U LLI O N AN D I TS B aoss

Assay of dross, Ag,

Wergh t of lead, ounces
ounces ounces per ton

If b ulli on i s SO ri ch i n dross that the lea d canno t eli q uate freely the nat ural
di stri b uti on of th e si lver will be much di sturbed Thi s wi ll account for t h e
,

fact that assays fromthe top of a bar someti mes run hi gher t han t hose fro mth e
bo ttom For i nstance Coppery bulli on fro mthe Ramshorn si lver m
.
, i ne I dah o , ,

contai ni ng so much dross that i f dropped on the floor i t wo uld break gave t o ,

Rhodes the resul ts gi ven i n Tabl e 86 under the head Fi g 3 59

2
. .

Accordi ng to Kem f N enni ng er A u al so s eem s to be co nc ent r ated

p ,

wi t h the Ag near the bo t to mof the bar as shown i n Table 88 .

Si m i lar resul ts have been p ubli shed by To rrey and E at o n ‘

.

T AB LE 88 .
-
R E LATN E D I STRIB UTI ON or AO AND AU I N BAR or LE AD BULLI O N

Sa mple from

Pri vate mmuni cati on by W

co . T atha m .

Pri vate communi cati on July , , 1 89 1 .

E ng . Mi n . J .
, 1 88 2 , xxxrv, 6 .

‘
Op . ci t .
,
1 886, x m 4 53
,
.
384 ME TALL URCY OF L E AD

the bars and repeati ng thi s on the o ther si de i n the opposi te di agonal In .

order to show where the holes are to be p unched i t is advi sable to use a templet of ,

sh eet i ron fi t ti ng over th e edges and li ttle sp r i ng p unches whi ch when tapped ,

wi ll mark the ri ght spo ts on the bar I t wi ll be no ted that no ne of the spots .

fall ei ther on the edge or i n the medi an line Two men usually work together .
,

usi ng 4 lb sledges -
One m
. an w ill hol d th e p unch ver ti cally wh i l e the o th er
.
,

gi ves i t th e first blow then bo th stri ke three or fo ur ti m , es wher eupo n a few ,

taps on the si des loo sen the p unch and br eak th e chi p In order to faci li ta te .

t he br eak i ng t he Openi ng at the poi nt i s m ,

ad e so m eti mes thr ee si ded ( as i n -

Fi g 36 2 ) i nstead of ci rc ular
. Tw o m en wi ll sam ple a ca rload of lead b ulli o n
.

wei gh i ng from 1 7 to 2 0 to ns i n abo ut 2 hr One seri o us Obj ec ti on to thi s .

method of sampli ng i s that on acco unt of the flow of metal the hardness of ,

the dro ss and the unevenness of the surface the chi p s fro mthe top Of the bar
, ,

are li k ely to be sm all er th an tho se fromthe bo tto m .

Reco m mendati ons by Kempf and Nenni nger and Austi n have not been
‘ ‘2

followed .

D ri lli ng i nstead of p unchi ng has been advoca ted but has not found favor , .

The chi p s Ob tai ned by sam

m
p li n g 9 c ar l o a d or a lo t are coll ec t ed i n a w ood en .

box m ,
el t ed and cast i nto a sam e bar
,
A NO 1 0 graphi te cr uci b le i s bro ugh t -
. .

appro xi m at ely to a wh i te hea t and tak en fromthe f urnace ;

the ch i p s are dropped i n and m el t q ui ckly ; the m etal i s sti rred

and po ured i nto an i ro n m old 2 in thi ck wh i ch gi ves a bar .

,

9 by 394 by M i n w e i gh i ng 6 l h or o ne 1 0 by 5 by M i n .
, .
, .
,

wei ghing 1 0 lh as shown i n Fi g 365 The bar i s cut i n “ .

,
. .

tw o along the do t ted li ne ; one h alf i s reserved for th e um pi re -

assay ; fro m th e o th er h alf th e fo ur sam ples (N os 1 to .

ea ch wei ghi ng a li t tle over M assay t on are cut o ut to be -

assayed I t i s essenti al th at the i ron m . old shoul d be cold

and th i ck so that the bar wh en cast shall soli di fy qui ckl y , ,

and the pr eci o us m etals have no chance to b ecom e unevenly

di stributed .

At the Delaw are Lead W ork s the sam ples used to be

melted at a very low temperature ( some sawdust bei ng added to make th e
r i si ng dross as dry as po ssi ble) the lead was po ured i nto a mold and the ,

dro ss rak ed out on an i ron plate and r ubbed Lead and dross were wei ghed .

and assay ed and t he resul t calc ulated as follows :

A . a+ B . b
"

Average assay
FB A
.

A= w ei ght of dro ss ; a = assay of dro ss ; B = w gh t of lead ; b assey of lead

ei = .

A num ber of such wei gh ts and assays have been gi ven i n Table 87 W here .

a larg e q uanti ty of lead b ulli on i s desi lver i z ed the method tak es too much ti m e , .

Wi th bulli on ri ch i n dro ss i t i s to be recom mended , .

E ng . Mi n . J .
,
1 88 2 , xxxrv, 6 .

Op. ci t .
, 1 33 .

Par melee , Met . Che m E ng

. .
, 1 9 1 6, xx
v, 56 1 .
 S MELTI NG LE AD ORE S I N TH E BL AS T F UR N ACE 385

Sawi ng bars as a m eans of samof pli ng was suggested by Patti nso n I t .

‘

was prac ti sed for a consi derable ti me at Pueblo Colo I t i s used at the plant , .

of the Internati onal Lead Refini ng Co w ’

i th bars of dro ss cast fromk ettles .

in w hi ch lead b ulli on i s mel ted and drossed previ o us to taki ng ladle samples -
.

The m ethod i s as follows : The b ulli on i s unload ed fromth e ca r on to an i ncli ned

i ron trough havi ng roll ers at the bo t tomover whi ch i t runs onto a table H ere a .

ci rcular sawis so arranged wi th a sli de and gauge as to make an inci si on halfw ay

T he c uts are m
m
t hro ugh t he bar ad e resp ec ti vely i n the first bar at one si x th
.
-

o f th e bar length i n the second at tw

-
o si x th s and so on , The sam ple fro a 2 0 -
.

t on lot w ei ghi ng abo ut 70 lb i s thoro ughly m i xed quar tered li ke an ore sam ple .
,
-

and then assay ed i n q uanti ti es of half an assay ton wi tho ut any previ o us m el ti ng ,

as resul ts Ob tai ned af ter m el ti ng are li k ely to be too low .

The f ur th er treatm ent of lead b ulli on that i s desi lveri zati on i s tak en up i n , , ,

Chap ter X .

1 77 S pei ss — The spei ss ob tai ned i n lead sm

. el ti ng i s pr i nci p ally an ar seni c al
.

spei ss as seen i n Table 89

,
Antim oni al spei ss i s occasi onally m
'
ad e i n smel ti ng .

sof teni ng sk im mings

T AB LE 89 .
— AN ALYS E S or SPE I S S

U p t0 0 . 01 4
Trace

7 1 60

( a) E mmo ns , G eology and I ndust ry of Lead vi l le. p 7 2 0 ; ( b) Dew

Mi ni ng ey. Bull et i n No 4 2 .
. Uni t ed
mm
.

S ta t es N at i onal Museum ,
”
p 5 2 ; ( c) Pri vate co
. uni cati on of M W Il es ; ( 11) Curti s.
“
Sil ver Lea d . .
-

Dep osi t s of E urek a N ev . , Monograp h VII, U ni ted S tates Geologi cal Survey. 1 884 . p 1 60 ; ( c) Bai li ng. .

m
.

Berg a utu n Z , 1 86 7 . xxxvr 4 1 9 ; (f) H ah n. Tr I nst M i n M et 1 809 -

9 0. v n
. 271 ; ( 5) A nn M i n Bel g
mm
. . . . . . . . , . . .
,

1 9 0 1 v1 . 2 7 0 ; ( h) E ng M i n J . 1 9 05 .
. 3 64 . . . . .

predominant element i n arseni cal sp ei ss i s Fe; the o ther metals usually

T he
present are N i Co Cu and to a small extent Pb Bi Au and Ag M ost spei sses
, , , , , ,
.

are prod uc ed i n co nj unc ti o n wi th m at te; the S co ntents of such sp ei sses po i nt -

to the solub ili ty of m at te i n sp ei ss

‘
Guyard calls attenti on to the absenc e
‘
.

J S oc Che 8 2
9 , xx 3 2 1 m I nd 1

m
. . . . .
, ,

H ulst, Tr A I M E , 1 9 1 4 , x x , 539
. . . . . .

—
Parravano Cesari s, syste As Sb, I nternat Zt Metaltogr ,
— m . . . 1 9 1 2 , 11 , 70 .

Junker, freezi ng poi nt curve As S, Zt anorg Che , 1 909 , -

-
. . m
. 89 .

E mmn o s, lac . ci t .
, p .
7 2 1 .

25
386 ME TALL URGY OF LEAD

of Co i n Ifi adville spei ss whi ch he fo und concentrated in the dross ski mmed ,

fromthe lead well H e also found as m -

uch as 1 0 p er c ent of grai ns of m
. etalli c .

Fe free fromAs i n Lea dvi lle sp ei ss whi ch i s unco m mon I t has b een already , .

stated th at sp ei ss alw ays co ntai ns sho ts of Pb and that wh en coar sely crys ,

talli ne less i s fo und than wh en i t i s fine gr ai ned Asregard s the presenc e of -

.

preci o us metals the fac t i s to be no ted that sp ei ss retai ns co nsi derable amo unts
,

of Au whereas very li ttle Au i s fo und i n m

, atte; sp ei ss assay s show fro ma trac e -

to 0 5 oz Au p er ton
. . The presence of m etalli c Fe i n sp ei ss furni sh es an
.

explanati on for the excess of Au ov er Ag usuall y fo und as Fe has a st rong ,

afii ni ty for Au I les gi ves as

l ’
.

P "
so a n a v erag e of 6 y e a r s oper a
’

ti o n that wi th ore assayi ng Ag ,

41 . 000 and Au oz .
p er ton

( ra ti o , 1 00 : the lead
b ulli on assa e y d Ag , and

Au oz .
( rati o 1 00 ,

the matte ,
Ag and Au
oz .
( rat i o ,
1 00 Pb
1 0 and Cu p er cent .
; and
the sp ei ss Ag and Au
oz ( r a
.ti o 1 00 An i dea ,

of the consti tuti on of sp ei ss i s

ob ta i ned by the study of the
followi ng bi nary alloys :
1 I ran arseni c — Thi s
-
. sys

te m been has studi e d by

Fri edri ch wi th i n
3
th e li mi ts of
3° “
g “n and p er cent . Fe, and

F1 0 366 — s Fe As
Alloy seri e .
— by D 1
?
Ck m a l
}
.

T h e c u rv .
e Of
}

Fri edri ch Fi g 366 show s the ,

.
,

exi stenc e of the chem i cal co m po unds FegAs wi th p er c en t F e fr ee z i n

,g ,
.
,

C FeaASQ wi th c prob bly of A w h

°
at 9 1 9 p e r ent F e ; a nd a F e s i t .

p er ce n t Fe fr ee.z i ng at ,
t he co m po un d F ed s, b ei ng the resul t of a

reac ti o n i n the soli difi ed alloy ta ki ng place at also the pr esence of an

°
eutec ti c wi th As 30 p er cent freezi ng at 830 C whi ch consi sts of FezAs .
,
.
,

and Fe hold i ng so m e As i n so li d sol uti on The all oys r epresenti ng ch em i cal .

co m po unds are ex trem ely bri ttl e; all oy s wi th less than 60 p er cent Fe are not .

at trac ted by the m agnet .

2 N i chal arsm ic — Accordi ng to Fri edri ch and Benni gson who i nvesti
-
5
,

gated thi s sy stemwi thi n the li m

. .

i ts of 0 and p e r c ent A s th er e e x i s t as .
, ,

1
See H of mn COppe
a ,
r, 1 9 1 8, 2 1 5
.

“L d S
ea mlti ng Wil
e ,
”
ey, NewYork, 1 90 2 , p . 1 29 .

MM argi e, 1 90 7, Iv, 1 2 9 .

8 10111 a . E i sen , v, 1 694 .

1 9 1 4 , xxx

Metallurgi e , 1 90 7, IV, 2 00.

388 ME TALLURGY OF LEAD

4 . Copper ars -
m —
i c The
curves of Fri edri ch and Bengaugh H ill are repre .
l -
’

senta ti ves for th i s sy stem I n the revi sed c urv e of Fri edr i ch Fi 6 Cu is
g 3 9 .
,

seen to formwi th As a sol i d soluti o n co ntai ni ng 4 p er c ent As at 684 C ; then

.
,
°
. .

follow an eut ec ti c wi th p er c en t Cu co nsi st i n g of s ol i d s ol uti o n Cu As and

— .
,

CugAs ; th e co m po und Ci l gAS contai ni ng p er c en t C u an d fr ee z i ng a t , .

and the hi dd en co m po und CU ‘AS) wi th p er ce n t C u for m e d a t N o , .

defini te i nform a ti on exi sts regardi ng the hori zonta l li nes at 604 and 307 C
°
.

—
5 L ea
.d arsen i c Se-
e § 1 6 . .

6 Other Md ots arseni c — Besi d e the pri nci pal m eta l s of a sp ei ss the freez
‘

-
. .
,

i ng po i nt c urves of whi ch have been gi ven th ere are li k ely to be p resent other
-

metals in small quanti ti es such as Pt ’

, ,

‘ ‘ “
Au Ag Bi Sn Zn Mn and others
’ s ’

m
.
, , , , ,

1 78 . Treat ent of S pei ss — The treat .

mnt of e p
s ei ss order to recover Pb Cu
in , ,

Ni , Ag, and Au has been and sti ll is a

problem difi cult .

At E ureka N ev Davi es devised alo

,
.
,

si m p l e meth od for th e r ecov ery of p rec i o us

metals fromthe spei ss gi ven i n Table 89 .

I t consi sted i n tapp i ng 800 lb of speiss .

so do to i nto a sm all cyli ndr i cal i ro n converter

Fm 369 l
— — i ned wi th fi re bri ck F i g 37 0 a dd i ng
Alloy seri es Cu As
-
.
, ,

from 2 0 to 2 5 p er cent li qui d lead and

. . .

i ntroduci ng from the bo tto ma blast of 1 7 oz pressure thro ugh a Mih pipe .
-
.

for 3 or 4 m in Thi s sti rred up the lead and spei ss and b urnt 06 som
. e As .

M o st of the Ag and Au was tak en up by the Pb; the li berated Fe corroded

the li ni ng so m ewhat but ate thro ugh o nly v ery slowly The converter w ,
as .

turned down and the co ntent di scharg ed i nto a cast i ron r ec ei ver havi ng the -

form of a slag pot the bo ttom of whi ch had a Mi n hole for tapping the
-

,
.

lead The desi lveri zed spei ss soli difi ed qui ckly following whi ch the still li quid
.
,

lead was tapped Best resul ts were ob tai ned when the lead assayed 40 oz Ag
. .

to the ton The desi lveri z ed sp ei ss w

. as th en a waste p rod uc t The claim .

was made that froma spei ss of the composi ti on shown in Table 89 p er

,

cent of the Ag and

. of the Au were extrac ted wi th a lo ss of Pb varying ,

M etallurgi e 48 4 . 1 908. V. 5 2 9
M et 1 9 1 0 m 34
.

J . I nst. .
, , , .

Fri edri ch Leroux Metall urgi e

-

, ,
1 908 , v, 1 48 .

Fri edri ch, op ci t 1 908, v 603

m
. . .
, ,

Fri edri ch -
Leroux , op . ci t .
,
1 906, ,
1 92 .

H ei cke Leroux, Z t
-
. anorg . Che m .
,
1 9 1 5, x cn , 1 1 9.

Fri edri ch Leroux Metallurgi e 1 908 v 1 4 8

-

, , , ,
.

H ei cke, I nternal Zt M ctallogr 1 9 1 4 VI 2 09 . . .

, , , .

Parravano Cesari s, -
op . ci t. , 1 9 1 2 , 11 , 1 .

Fri edri ch -
Leroux Md oll argi e , , 1 906, 11 1 , 4 77 .

Schoen, op . ci t .
,
1 908, v, 73 7 .

Ri ckard, E ng Mi n J . . .
,
1 888, x t v, 4 74 .
 S MEL TI NG LE AD ORES I N TH E BLAS T F URNACE

from 5 to 8 p er cent At Frei berg Saxony and Oker H arz Mountains Pb .

,
l
,
’

bea ri ng spei sses are treated i n m anners whi ch m eet local req ui rem ents .

T h e Frei b erg speiss contai ns Fe Ni Co Pb Cu Sb

As 11 d Ag
. . Au,
Pt p e r cen t I t i s d e a d ro as ted a nd th e n .
-

sm el t ed wi th pyri te
gal ena li th arg e low i n A g ,
an d m at te s la g
,
i n a l ead b la st ,
-

fur na ce Earli er work smel ting rawspei ss i n a reverberatory furnace wi th

.
, ,

the ad di ti on of an eq ual am ount of flux consi sti ng of 66 p er cent bari te and .

34 cen t q uart zi te to for m. lea d b ulli o n spe i ss a n d m a t te h a d show n t h at , , ,

Fro .
3 70
— D avi es co nverter for desi lveri zi ng sp ei ss .

as long as the refined spei ss assayed over 2 5 per cent Fe a m atte contai ni ng .
,

Cu, Pb, Ag, and so m e Ni w as ob tai ned whi ch separated r eadi ly fromthe

sp ei ss The . sp ei ss whi ch amounts to 2 5 p er cent of the ori ginal ch arged

, .
,

contai ns Fe N i Co Pb Cu Sb As 11 . d .
, Ag Au
Pt cent p er .

Th e Ok er sp ei sses are represented by the follo wi ng two analy ses Fe Zn

Ni Co Pb Cu Bi Sb As S
AgAu p er cent .
; and Fe Zn Ni Co Pb Cu
Bi n d . .
, Sb . As S AgAu cent p er .

T he m etho d o f tr eat ent i s m a ro ast smelti ng i n a rev erb eratory furnace

-
.

The produc ts are copper to be granulated and slag The copper granules .

1
H ilbner, Clack an] , 1 90 5, x u , 6.

H of man ,
Mi n . I nd .
,
1 905, xxv, 41 4 .

H uhn, Gl itch an ] ,
1 905, x u , 1 1 65 .

H of man , i bid .
390 M E TALLURGY OF L E AD

have the followi ng compo si ti on: Fe N i Co Pb Cu

Bi Sb As Ag
c ent ; Au to tal p er .

the slag goes b ack to the blast f urnaces There are i n use tw o r everb era .

t ory furnac es the h ear th s of wh i ch are b ui l t i nto i ro n pans water cooled at

, ,
-

si des and bo t to m wi th m ovable roof One furnace has a hea r th

,
by .

ft and a grate
. by ft ; the hear th of the o ther i s by 6 56 ft . . .

and the grate by ft Bo th furnaces have under grate b last . Th e -

.

bo tto mof the hearth consi sts of a layer of marl tam ped down firmly followed ,

by a course of bri ck lai d dry The worki ng bo ttom ram med i nto place i s a
.
, ,

mi xture of 2 0 parts shale and 80 parts marl gro und to pass a 1 mm hole Th e -
. .

metal bath of furnace N o 1 i s ft d eep t hat of N o 2 . ft ; the copper i s .

,
.
,
.

tapp ed fro mbo t h si des i nto granulati ng basi ns The m ode of Operati on i s as .

follo ws : Charge 3 5 tons poor spei ss i nto th e smaller or 5 tons i n the larger
.
,

f urnac e; bri ng to a red heat and roast ; mel t when no more fumes are gi ven off ;
ski mthe dro ss wh i ch has a m etac ap pearance and t urn on the b last ( p r essure , ,

8
3 4
— 0 m m H g) ; ski
. m t h e sl ag wh i ch t a k es up F e S b Pb a n d Z n i n
,
t h e ord er , , ,

gi ven; lower the temperature wh en slag ceases to form unti l the bath becomes , ,

p a st y an
,
d t ur n o ff th e bl a st t o a ss i st vol ati li zati on of As ; fire up agai n wh en

fumes of As cease to be evolved ; conti nue cooli ng and firi ng up unti l no more
As i s volati liz ed The sp ei ss i n the furnace has b ecom
. e enri ch ed to 75 p er c ent .

Cu . Charge 2 5 3 to ns ri ch sp ei ss ; fi re up ; roast as m
— . uch as po ssi ble and li q uefy
charge; ski mthe dro ss ; turn on blast ; ski mslag ; cool and reheat as befor e to
dri ve off As I n or r
d e t o ob ta i n s a t i sf c ory gra l es the C content o ugh t
a t nu u —
.
,

to rang e b etween 90 and 93 p er cent I t tak es 4 0 hr and tons coal to refine . .

6 5 tons charg e i n furnace N o 1 ; the

. to ns of hear th m ateri al form
. ing ,

th e worki ng bo ttom lasts 9 charges W i th furnac e N o 2 the 8 ton charge takes

,
. .
,
-

4 8 hr a n d
. t o n s co a l ; th e t o n s h ea r th m a ter i a l of t h e work i ng bo t to m
lasts 6 charges .

Roasti ng of spei ss wi th the obj ec t of expelli ng the As as A5 30” and usi ng the
Fe as a b asi c flux ofi ers m any di ffi c ul ti es on acco unt of the form ati o n of m etalli c

arsenates ( M etgAn g) whi ch are not deco m po sed by heat The reduci ng .

roasts advocated by Plattner to convert arsenate i nto arsenide do not appear

1
,

to w ork sati sfactori ly and are rather tedi ous leng thy and thereby expensi ve
it
, , , .

A very efii ci ent m etho d of expelli ng As i s to crush the sp ei ss m i x i t wi th pyri te ,

concentrate i n the propor ti on of 1 0 1 and roast i n a reverb eratory f urnace ; ,

the pyri te eli m i nates a l arge par t of the As as As sy and the SO ; form ed i n , ,

roasti ng decomposes MetAs converti ng i t into Met S04 , .

H eap roas ti ng i n lo ts of 50 t ons whi ch b urn fro m2 to 4 week s i s a m

-
et hod , ,

whi ch wi ll be used only i n excep ti onal cases The erec ti on of a heap requi res .

speci al a t tenti on i n order to i nsur e a sa ti sfac tory draf t ; the prod uc t i s uneven
so that i m perfectly roasted spei ss has to be sorted out crushed and ret reated , ,

i n a r everberat ory furnace .

“
Metallurgi sche Rti stp rocesse p 2 52 ,
. .

Pearce, Tr A I M E 1 889 90 xvm 6 2

.
— . . . .
, , , , 4 57 .

H ow -
m
e Ca pbell Knight, op -
. ci t , 1 907, xxxvur, 1 6 2 .
.
392 ME TALLURGY OF LE AD

a consi derable porti on of i ts As whi ch p asses off fro mthe throat of th e furnace
as a yellow bro w ni sh fum e of -

In conver ti ng the spei ss m atte th e Pb a large par t of the Fe and so m e Cu -

, , ,

and Ni go wi th the sl ag whi l e th e co ncentr ated spei ss retai ns the rem

. ai ni ng Ni , ,

Cu and Fe
, The spei ss m ay be gr anul ated as i t i s p o ured fro mthe co nver ter
.
,

and treated by a w et process for the recovery of N i Cu and preci ous m etal , ,
.

1 79 Matte — The m at te p rod uced i n the lead bl ast f ur nace usually contai ns
. r

—
Fe 4 5 60 Pb 1 0 1 5 Cu 5 1 0 S 2 2 2 5 per cent
—
, It i s a m i xt ure m
-
ai nl y of sul
, ,
-

p hi d es of F e Cu a nd Pb wh i ch fre q u entl y co nta i ns

, s m all q u anti t
,
i es of m eta lli c ,

Fe Cu and Pb
, Besi d es the m
, ai n sulphi des th ere are fo und sulphi des of Zn
.
,

Ni Co Mn Ba perhaps N a and K som

,
1
,
11
e arseni des and slag
, ,
Many m at t es , , .

co ntai n so m e Fe304 ; thi s i s m ore frequently the case wi th copper mat tes ’
,

formed i n blast furnaces run wi th pyri ti c efi ect than wi th lead mat tes p roduced ,

under stro ngly reduci ng condi ti ons The for m ati on of Peao4 i n sm el ti ng ha s .

b een consi dered i n § 1 34 and 1 3 5 Accordi ng to Mostow i t sch the m

‘
agneti t e .

in m at te i s present as a soli d soluti on of F00 and Pezo4 whi le H ostetter and ,

Sosm an hold that there ob tai ns a soli d soluti on of P030. and Fe.o.
6 .

T AB LE 90 — . AN ALYS E S or MArrE

85
00 Trace
00 N one Trace

02

50

O O O O O O O O O O O O O O O O O O O

() p“er t o n
a ounces .

Met allh utt enkunde , 2 ) W al deck . S t rei fzoge durch di e Bler und Srl be rh ut te n
Q

1 Bai l i ng , 86 (
mm
p
m
-
. .

dea Cherh a K na p p . H al le. 1 00 7 , p 2 2 ( 3 Ocsterr J ahrb 1 801 . t ) A nn M i n

I Sm
"
s . 2
-

mm m
. . . . . .

1 9 01 , VI . 2 70 ( 5) Pri vat e co . uni ca t i on. W H ov ard ( 6) Sa e. M W Iles 7) e. R D Rh od es . . . . . . . . .

1
Godshall , E ng Mi n J . . . 1 900, max 44
mm3
, , .

Canby, op ci t , 1 899 , . .
, .

H of man ,
Metallurgy of Cop per ,
1 91 8, p . 2 1 4.

Pri vate co mmuni cati on 1 91 7

mm
.

mS
,

J Arn Che
. . . oc , 1 9 1 6, 100
.
,
1 1 88.
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN ACE 393

Analyses of mattes are gi ven i n Table 90 whi ch gi ves exam ples of normal ,

and co ncent r ated m attes The hi gh percentage of Pb i n the m atte prod uced
.

at Claust h al i n 1 86 7 w as caused by the area of the f usi on zo ne whi ch w as m ade ,

large i n order to obtai n a low temperature and to di mi ni sh thereby the slaggi ng

of the bri ck furnace wall s ; -

but the low tem perature

resulted i n an i mperfec t
decomposi ti o n of PbS I n .

th e m odern furnace analysi s ,

of 1 907 whi ch has a con ,

t rac ted water cooled m el t -

i ng zone the lead content i s ,

-

nor m al The analyses show

.

t hat on the whole the Pb

content ri ses wi th that of w w
, ,

o so so 70 so so 40 so 20 10 0 9 ? 0
fin 1° 2° 3° 5° 7° 8° 90 100 951 5
t he Cu wh ereas the p er
Fm 3 71
-

,
— Alloy seri es FeS Fe
centage of Fe falls
-
. . .

1 80 Consti tuti on of Matte — The co nsti t uti o n of m

.
1
atte has b een revealed .
~

t o a c er tai n extent by i nvesti gati ons i nto the b i nary system s of m etal and sul

p hi d e a
,
nd of su lph i des w h i ch have been made i n recent years Ternary sys ,

t em
.

s of sulphi d es k nowl edge of w hi ch wo uld supplement the resul ts ob tai ned

,

by the work on the bi nary have not b een studi ed so far , .

1 — —
FaS Fe The freezi ng poi nt c urve . .
-

has b een t raced by Tarnm ann Trei tschk e

1 -

and Fri edri ch The c urve of the latter

’
.

i s gi ven i n Fi g 3 71 ; i t shows t hat the .

tw o co m p o n e n t s for m a n e ute c ti c m i x t ure

wi th 85 p er cent FeS and 1 5 per cent . .

°
Fe freezi ng at 983 C ; also that Fe can , .

hold i n soli d sol uti on less than 3 per cent .

FeS and FeS l ess than 1 p er cent Fe , . .

2 C — C14 — The c urve of H eyn . .

Bauer i s gi ven i n Fi g 3 72
‘
It shows . .

t hat the freezi ng poi nt of CugS whi ch -

li es at 1 1 2 7 C i s lo wered by addi ti ons of °

.
,

Cu unti l the tem perature has fallen to

40 so that a f urth er separati on of Cu

Fro Alloy senes fro m a m i x t ur e of t-

h e tw o co m po ne nt s

does not lower the tem

.

perature unti l the ,

co mpo si ti on of the ori g i nal has been changed to 1 0 Cq and 90 Cu wh ereupon ,

th e curve hori zontal at ,

fal ls qui ckly to the eutecti c poi nt of p er

and ri ses si m
°
cent CugS at
. i larly to the freezi ng poi nt of Cu at 1 084 -

1
Fulton Goodner, Tr A I -
M E 1 9 08 , xxx r
x, 584
mx
. . . . .
.
,

1
Zt . anorg . Che m .
,
1 906, x , 3 2 0; M etallurgi e ,
1 90 7, I V, 54 .

1
Op . ci t .
,
1 9 1 0, V1 1, 2 57 .

Metall urgi e ,
1 906, 1 11 , 76 .
394 M E TALLURGY OF LE AD

more recent re earch of U a fi gi ve data di fi ri ng larg ly fromtho

The s r zo
‘
s e e se

of Bauer H eyn; i t tate that the mel ti ng poi nt of Cu i s lowered by ad di ti n

-
s s -
o s

of S unti l
. lloy wi th an a
p er ce n t .

Cugs has been form ed ; that i t ri se s w i th

fur ther addi ti ons of S unti l a separati on
i nto tw o layers ta kes plac e the upper ,
°
freezi ng at 1 1 2 1 C and t he lower at .

H e finds that li qui d Cugs can

di ssolve p er c en t C u a n d p e r .

o 1 100 cent S and that Cu and S rem

.
, ai n i n

sol uti on upo n soli dificati o n; but that

on f urt her cooli ng the CugS C u sol u —

,

ti on i s t ransfor m ed fro m B Cq — to
a CugS
-
and —
the CugS S soluti on
,

assum es the m ore stable form of

ar CugS -
The form ati on of m
. oss cop
p e r i s expl ai ne d by th e br ea ki ng up o f -

a soli d sol uti on havi ng an exce s s of Cu ,

i n the transform ati on of cu. s t o ano t h er

modi ficati on (see AggS Ag below)

12 16 N 26 28 83
— .

P bS —P b Thi c urv h b n
— Allo seri es N i 583 N i 3 s e a s ee -

FI G
. .

3 73 y
-
. . .

di sc ussed i n 539 .

study of Bornem
N i S results of the Ni — The ann of t hi s ser
1
s of
ie
4
-

o z . .

alloys wi t hi n the range of 0 and 3 1 p er Pea C nt Ac

w 40
e
-
,

cent S are gi ven i n Fi g 373 They

. . .

show that the com ponents form one

chem i cal co mpound Ni . s, freezi ng at ,

7 78
°
C an d p rob a b
.ly ,
a s eco n d N i . s. ;

that there exi sts one eutec ti c of

°
Nl Ni asg freezi ng at 644
—
, C and .

probably a second Ni ssg Ni 385 Be ,

-
.

t ween 0 and p er c e n t S he fo u n d .

mi xtures of Ni and Ni ssz; and bet ween

and 3 1 per cent S m

m
i xt ures of .
,

s. and H i s i nv esti gati ons as

well as those of o thers have shown11
40 so
t hat Ni S heated i n a neutral atm
60
o sp h ere Po C nt -
t o ,

gi ves 03 S unti l i t has been changed Ft o 3 74 — —

Alloy seri es Ag s Ag . .
, .

to Ni aSz In the older li terat ure there

.

i s recorded the co m pound Ni gS Tho ugh Munster and Sch weder recogni zed
‘ 5
.

1
Ann I nsti l Polytech Pi erre lo Grand ,
. . . 191 5, xx m 59 3 , , through J . I nst . Met .
,
1 91 5. XIV.

1
Metall urgi e , 1 908, v, 1 3 ; 1 9 1 0, vn 667 .

m
,

H ayward, Tr A I . . . M . E .
,
1 9 1 4 , x nv ,
1 41 .

Berg H i alcnrn , Z 1 87 7, xxxvr, 1 95

m
. . . .
,

1
0p . ci t .
, 1 879 , xxxv , 1 8 .
396 M E TALLURGY OF LE AD

freezing W ei dm
at
°
ann plac es the eutec ti c poi nt wi th
863 C .
p er cen t , .

FeS and p er cent P b s al so at B o t h rese arch es agr ee i n dr aw i ng t

. h e ,

eutec ti c li ne to the or di nates t hus provi ng th at the sulp hi des are m ut ually ,

i nsol uble i n the soli d state .

—
8 FaS Z nS
.
— In the i nvesti gati on Fri edri ch .
1
used as raw m ateri als

pyrrhoti te and blende Hi s curve Fi g 376 coveri ng a range of 0 to 60 p er cent .

,
.
,
.

Per nni c
60 50 40
m ww '

l oceo

0 10 m0 3 40 50 60 70 80 90 100

F m .
3 76
— . All oy seri es —
FeS ZnS . Fro 3 77
. .
— —
Alloy seri es FeS A3 38 .

ZnS, hows that the components for man eutec ti c wi th 9 5 p er cent FeS and
s .

5 p e r c en t Zn s fr ee zi ng at 1 1
. 8 8 C and th a t Z
, n S i s so luble i n FeS to th e
°
.
,

extent of p erhaps 3 p er c ent .

9 F eS.
—
AggS — T he d i agram of Sch oen 2
g i v
.e n i n F i g 3 77 show s t ha t th e ,
.
,

co mponents for man eutec ti c w i th 1 1 per cent FeS and 89 p er cent Aggs . .
,
°
freezi ng at 600 C and that they are sli gh tly solubl e i n one another so tha t
.
,
-

wi thi n the li m i ts of m attes usually prod uced AggS m ay be co nsi dered as ,

Per Cent. 014 4 8

Per Cent.
l oo wso moo ao w60 fl 10 0

0 10 20 30 0 60 60 70 80
Per Cent . PbS
w1w o mao s w o ao oo v o ao so
Per Cent, 2 3 8
m
FIG 8 — Alloy seri es Cug —
S PbS FIG — Alloy seri es Cues Z nS
37 3 79
-

. . . . .

formi ng a soli d soluti o n wi th F08 The hori zontal li ne at 1 75 denotes the .

°

transfor m

m
ati o n of Aggs .

10 C
—PbS
.
— In the i nvesti gati on of thi s system Fri edri ch used gal ena
.
1
,

wi th p er c ent P b wh er ea s P bS co n t ai ns p er c e
.n t P b H i s,
c ur ve Fi g . .
,
.

37 8 sho
, ws a n e ut ec t i c wi th 5 p
1 er c en t C ugS and 4 9 p e r c ent PbS fre ez i ng a t . .
,

1
Op . ci t .
, 1 908, v, 1 14 .

1
Op . ci t .
,
1 9 1 1 , v m73 7 ,
.

1
Op . ci t .
, 1 907, I V, 6 71 .
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN ACE

540
°
C . fro mordi nate to ordi nate thus p rovi ng that
The eutec ti c li ne extends ,

the co m ponents are mut ually i nsol uble .

— The zi nc sulphi de used by Fri edri ch w as blend e w

—
1 1 CasS ZnS .
1
i th
p er c ent Zn wh er eas Z nS co nt ai ns p er c en t Zn . Hi s c urv,e F i g 3 79 . .
,
.
,

sho w s that the t w o co m p o nen ts h a v e no afli ni ty wh at ev er for on e ano t h e r a n d

1 700
100 so m Per Cent. P68
70 60 50 10 ( I so 10 0

so 0 60 N 100 o wzo ao wso eo ro so wm

o
Per On t, M S

FI G — Alloy seri es CugS Aggs FI G 8 — PbS—Z S

380 3 1 n
-
. . . . . .

aremutually i n ol ubl I t doe not furni h an e planati on of th fact that th s e . s s x e e

p n
resec of Cu i n ma t te i f avor abl tethe coll c ti on of ZnS I t ha b n how n s e o e . s ee s

abov th at ZnS i li gh tly olub le i n F S ; i t m

e ay be po i bl that t h pr nc s s s e ss e e ese e

di ssolvi ng p o wer of FeS

m
of CugS i ncreases t he .

12 C — Aggs.
— The c urve of t hi s system Fi g 380 traced by Fri edri ch .
1
,
.
,

show s t hat the co m ponents form soli d

t u .S
soluti ons t hro ughout ; t he m i ni m um li es no so s é no

at 6 77 C wi th an appro xi m at e co m posi
°
.

ti on of 30 p er cent CugS and 70 p er cent . .

Ag2S The c urve gi ves the reason for

.

the well known fac t that the presenc e of 9 1 1

36
-

Cu. S i n a m
,
atte gr eatly favors the collec 5700
ti on of AggS
2
.
00°
— — The di agramof Fri ed
ri ch
1 3 PbS Z nS
1
.

based upon the use of blende and

2 .

g al e n a as n o t ed abov e i s g i v e n i n F i g ,
.

3 8 1 . I t sho w s a n eu te c ti c w i t h 9 2 p er
0 1° 20 so 40 50 so 70 so som e
cent PbS and 8 .
p er c en t Z nS fr eez i ng a t P o a t P18 .
,
r - .

Fm 38 2
°
1 044 C and the i nsol ubili ty of ZnS i n
.
,
— Alloy seri es PbS A8 5 . .
-
1

PbS .

14 . gal ena as i n previ ous work menti oned

—
P bS A g, S .
— H ere Fri edri ch used 1
, ,

as one co mponent The curve Fi g 38 2 shows an eutec ti c w i t h 2 3 p er cent .

,
.
,
.

PbS and 77 per cent AggS freezi ng at and t he sol ub i li ti es of t he com .

,

1
Op . ci t .
,
1 908 , v, 1 14 .

1
Op . ci t .
,
1 90 7, IV,
6 71 .

1
Op . ci t .
,
1 908 , v, 1 1 4.

O? ‘ ca” w 4 79 , °
398 ME TALLURGY OF LE AD

p onents,
form AggS
i ng wi th abo ut 6 per cent of PbS a soli d soluti on and PbS .
,

wi th abo ut 3 p er cent of AggS The hori zontal li ne at 1 75 i ndi cates for the . .
°

t ransfor m ati o n of AggS .

—
1 5 P bS S bssa —. The resul ts of the st udy of Wagem ann are gi ven i n Fi g
1
. .

8
3 3 T. h ey sho w an eut ec ti c co mpo sed of Sn 3 and 2 PbS Sn ;; w i th 1 7 per .

2 p as
“
P 3 11 3 s
'

o ro m o so eo ro so so r
ao c oo
Per Cent 1 1 68 P“Cent , 3 3 3

F1 0 8 — All i P —
bS Sbssg Fro 8 — Alloy seri es PbS SnS
3 3 oy ser es 3 4
-
. . . . . .

°
cent PbS freezi ng at 4 2 6 C ; the i nsolubi li ty of PbS i n
.
, a soli d sol uti on .

of Sn ;; and 2 PbS Sn a between 44 and p e r. c en t P b S b e low .

,

t he chem i c al co m po und 2 PbS Sn ; freezi ng at and a sol i d sol uti o n of .

,

2 PbS Sn 3 and PbS to t he extent of

.
p e r c en t P b a t .

The research of Jaeger gi ves di fi eri ng results H e fo und one hi d den chem i c al
'
1
.

co mpo und 2 PbS Sb2S3 at 609 (j amesoni te) a second co m . po und 5PbS 4 Sb, S ; °
, ,
.

°
at 57 0 ( pl ag i o n i te) a n d a n e u t ecti c o f ,

noso so 10 o
pl agi o ni te and sti bni te wi th 80 p er c ent PbS .
,

u s freezi ng at 4 9 5 C °
.

“
Pelabon fo und an eutec ti c w i th 2 2 m ol .

PbS and 70 m ol Sn a freezi ng at 4 8 2

°
C . .
,

one hi d den chem i cal co m po und PbS Sb, S ; .

( zi n k en i te ) a t 5 6 8 C a n d a se co n d c o m °
.
,

pound 2 PbS Sn a (j amesoni te) at .

1 6 P bS S nS
— — The data of H ei ke are 1
. .

gi ven i n Fi g 384 H e finds that PbS melt . .

,

i ng at 1 1 06 C form s a soli d soluti o n w

°
i th
o 10 20 wwww10 wso no
.
,

P C nt 2 8 as m er uch as 8 p er cent SnS ; and th at SnS

e . 11 .
,

Fro —
Alloy seri es ZnS Ag s m e l ti n g a t for m s a t i ts freezi ng t em
g
p e r

at ure a so li d sol uti o n w

. .

i th p er c en t .

PbS ; he beli eves i n the exi stenc e of t he chem i cal co m po und PbSnS, wi th a
mel ti ng poi nt of 880 C -
°
.

1 7 Z nS AggS
— — “
The c urve of Fri edri ch gi ven i n Fi g 385 sho w s an eutec ,
.
,
. .

1
Op . ci t. 1 9 1 2 , 111 , 5 ,
1 8 53 7 .

VI I I I nternet Congress App} Chem, 1 9 1 2 ,

,

1
. . . 11 , 1 39 .

1
Co mpt . rend .
,
1 9 1 3, CLVI , 705 .

1
M etall urgi e, 1 9 1 2 , D1 , 31 3 .

1
Op . ci t.
,
1 908, v, 1 14 .
400 ME TALLURGY OF LE AD

charge of blast furnace all the Au and from60 to 70 per cent of the Ag
a ead l ,
.

wi ll be taken up by the lead bul li on .

The laboratory experi m ents of Mostow i tsch have shown that the am
1
ount

of Au and Ag extrac ted fro mmatte by means of Pb i s proporti onal to the

am ount of lead used ; that wi th 80 lb of lead to 1 00 lb of matte all the Au . .
,

enters t he lead bul li on and that w i th eq ual wei ghts of lead and m ,
at te o nly ,

7 p
2 e r c en t of th e A g i s r ecov . e r e d i n t h e l e a d b u lli o n H e e x pl ai n s t h e i m p e r .

fect yi el d of Ag by the reac ti on t hat i s ,

AggS i s co m pletely deco m p o se d by P b ( s e e a l so

Fromthe bi nary system s studi ed i t i s evi d ent t hat CugS i s a powerf ul

solvent for AggS and PbS and FeS have a co nsi d erable tend ency i n t he sam
,

,
e

di rec ti on As regards Au a good solvent i s fo und i n Cq the presence of Aggs

.
,

appears to act favorably up on carryi ng Au i nto m at te; the o th er sulphi des h av e

not m uch efi ect H owever m etal s such as Pb Cu and Fe have a st rong

'

.
, , , ,

tendency to com bi ne wi th Au .

21 N i ckel Matte
.
— The bl ast furnace m atte usually co ntai ns li t tle N i and
.

Co . A case of speci al i nterest i s that of the non argenti fero us lea d ores of -

So utheast Mi sso uri whi ch carry sm all am ounts of Ni and Co whi ch are co n
centrated i n the m atte w hen smelted i n the blast furnace At M i ne la M o t t e 1
.

the first m at te carri es fro m3 to 3 5 p er cent Ni Co fro m0 5 to 1 p er c ent . .

,
. .

Cu and from2 0 to 2 5 p er c ent Pb

, When thi s i s roasted i n a reverberato ry . .

f urnace there must rem , ai n when i t co m es to be used as i ron flux fro m5 to 6 , ,

p er c en t S i n t h e m a
.t te if th e lo ss of N i a n d C o by s l a gg i n
,
g i s t o b e a vo id e d .

In the sam e w ay the second m at te ( 5 6 Ni Co ; 2 0 30 Pb; 1 2 Cu)

— — — wh en ,

roasted req ui res from 7 to 9 p er cent S to reduce the loss by slagging ; i t

,
.

i s then sm el t ed wi th si li c i o us m att er to a t hi rd m —
atte ( 1 2 1 7 Ni Co ; 3 5 4 0
—

Pb; 3 5 Cu) the slags nevertheless assayi ng

—
, 5p e r c e n t N i c o an d f ro m 2 .

to p e r c en t P b A t t e m p ts a t f u r .th e r co n c en t.r a ti o n i n a r ev e r b e ra t o r y
f urnace proved unsuccessful the slags carryi ng 5 p er c ent Ni Co and 5 p er ,
.

cent Pb Thi s i ll ustrates the di fi culty of concentrati ng Ni co i n a matte wh en

. .

Pb i s present whi ch appar ently dri ves th emi nto the slag
, The Ni can then be .

recovered only i n part and the Co not at all There rem ai ns the i nt rod uc ti o n .

of As to for ma spei ss N eill used thi s m ethod succ essfully . The experi m enta l .

f urnac e h e b ui lt was 30 i n wi de at the tuyeres and 4 8 i n at the charging doo r ; .

,
.
-

the hei gh t fro mtuye res to chargi ng door w as 6 ft 6 i n ; the cruci ble 1 8 i n -
. .
, .

deep w as par tly i nternal par tly external and had a si phon tap
, , H e ob tai ne d ,
-
.

a spei ss w i th p er c en t N i C o ( n t h i d of w hi ch w a C o ) e c en t P b
o e r s p r -

,
. .
,

and p er c en t C u Th e m a t te t h a t for. m e d c o nta i n

. e d p e r c en t N i C o .
,

8 p er cent Pb and 7 p er cent Cu to be retreated ; the slag from

.
, to .
,

p e r c e nt N i c o a n d fro m t o p e r c e n t P b
Treatm
.
,

Th e obj ect of treati ng m

. .

1 81 . ent of Matte, G eneral — atte i s to

ex trac t the Ag and Au by m ea ns of Pb and to concentrate the Cu i n a sm all ,

am ount of Cu ri ch ma tte whi ch i s ei th er sold to cop per work s or bro ugh t

-

1
M et Chem E ng 1 9 1 6 xrv, 703
m 634
. . .
, , .

1
Neill Tr A I M E , . . . 1 884 8 5, x -

, .
 S MEL TI NG LE AD ORE S I N TH E BLAS T F URN A CE 401

forward to m etalli c 00pp er to be d esi lveriz ed by vi tri olizati on or elec troly t i c

refini ng E lec trolysis of mat te has been tri ed but has not been successful
.
1
, .

All concentrati on sm el ti ng of m atte fro ma lead blast furnace has to be

-

prec eded by an oxi di z ing roast in order to eli mi nate some 8 and to oxi diz e so me
Fe that i t m ay com bine wi th Slog and enter the slag Pyri ti c smel ti ng as 1
.
,

p r a c ti s e d w i t h copp e r m a t te c anno t be a ppli ed to lead m a t te on acco u n

,
t of
excessi v e lo sses i n Pb and wi th thi s of Ag whi ch are unavoi dable , The , .

roasted or blast roasted m atte i s sm el ted i n the lead b last f urnac e unti l a m atte

wi th about 1 4 p er cent Cu i s ob tai ned The fur ther trea tment may be ca rri ed
. .

o n i n the blast furnace the r everb eratory furnac e or the co nv er ter , , .

1 82 Roasti ng and Blast roasting of Matte

.
— Roasti ng m ay be carri ed on

i n heap s stalls k i lns and reverb eratory furnaces

, , , Th e choi ce of m ethod wi ll .

depend m ai nly upo n the val ue of the m at te and the co st of operati ng ; a ri ch ,

matte must be roasted q ui ckly so as not to lock up too much money for several
month s .

In roasted m at te
1
the ex ternal part of each pi ece or pellet contai ns m
, or e
Ag and Pb than the i nteri or Any dust that i s m ad e i n handli ng roasted m
. atte ,

com i ng fromthe surface wi ll cause consi derable lo ss ; agai n if expo sed to rai n , , ,

Ag. SO 4 form , ed in roasti ng i s lik ely to be lo st by leachi ng ,

.

Roasti ng i n h eaps and stalls has b eco m

‘
e ob sol ete i n th i s co untry ; i t i s stil l

i n operati o n i n som e E uropean plants but i s bound to be repla c ed ther e by ,

blast roasti ng as has been the case her e .

Roasti ng i n ki lns ca rri ed on i n works of the H arz Mo untai ns Prussi a and

, , ,

o f Frei berg Saxony whi ch are forced to take car e of th e sulph uro us gases by
, ,

co nverti ng th emi nto sulphuri c aci d has not b een prac t i sed here as far as the , ,

wri ter i s aware D etai ls of these three roasti ng methods are contai ned i n the
.

p re c e d i n g ed i ti o n of t h i s book .

Roasti ng m at te i n the reverb eratory furnac e wh i ch w as co m mon prac ti ce ,

until w i thi n a fewy ear s has b een replaced alm o st wholly by blast roasti ng wi th
,

si li ci ous m ateri al as flux on acco unt of the sup eri ori ty of thi s proc ess as r egard s
,

cheapnes s small lo ss i n metal and the advantage accr ui ng fromsmel ti ng blast

, ,

roasted lum ps of oxi di zed matte and flux r ather th an the pulver ulent produc t of
t h e reverb eratory furnace H and rev erberatory furnac es used to be i n greater
.

fa vor than m ech ani cal roasters as th e form er gave a b et ter eli m i nati on of S, ,

a nd the fusi bi li t y of m at te caused m uch cak i ng on the h ear ths of the latter .

Som e hand rev erb er atori es are sti ll i n op era ti on i n spi te of thei r low tonnag es

a nd hi gh costs of op erati on Li ttle need be added to the fac ts record ed in .

T able 4 2 as r egard s the hand reverb eratory furnace .

D esc ri p ti ons of m echani cal r everberatory roasti ng furnac es and d ata of

’
t hei r work are gi v en in the precedi n edi ti on of thi s book and i n the wri ter s
g
“M
etall urgy of

1
H of man ,
“Metallur
gy of Copp er, 1 91 8, p 4 8 2. .

1
H of man ,
op . ci t
.
p 89
, . 1 .

1
Platt ner, “Di e Metallurgi schen Rostp rocesse, Frei berg,
856, p 2 05 1 . .

1
Canby, E ng Mi n J , 1 908, W V, 7 1 9 ; form
. . . ati on of sulp hi de i nerals m .

1
M cGrawHi ll Book Co , Inc , NewYork, 1 9 1 8
-
. . .

26
402 ME TALL URCY OF LE AD

In recent years the Wedge roasti ng kiln has overcome by careful reg ulati on ,

of tem perature the fusi on and th ereby the adhesi on of mat te par ti cles to the
,

hear th Thi s furnace and i ts work have been consi dered in §9 2

. .

Blast roasting m atte Th e average com . po si ti on of the first blast f urnace

matte has been gi ven i n 51 78 and Table 90 I t shows that the matte must be .

readi ly fusi ble and that i ts S content i s too hi gh for a sati sfac tory blast roast
,
-
.

The reduc ti on i n S i s accom pli sh ed ei ther by rough ro asting the m a tte and -

ad di ng the fl ux es nec essary for sm el ti ng or addi ng to the rawm at te a diluent ,

( sili c i o u s m a te r i a l ) t o t he ex ten t of about 2 0 p er cent whi ch wi ll counterac t .

premature fusi on and reduce the S content to the amount requi red for b last -

roasti ng As matte and flux have to be inti mately mixed i t i s necessary to

.
,

reduce bo th to a sui table siz e say in and sm aller , . .

Matte i s ob tai ned fromthe blast furnace ei ther i n the formof a so li d cone
or cake whi ch has to be crush ed or i n the li q ui d state when i t has to be granu
, , ,

lated Cakes of m
. at te ri ch i n Fe di si nt egr ate readi ly wh en expo sed for a few

days to ai r especi ally when thi s i s moi st ; they are crushed i n break ers and
“
,

rolls usually set to 9 i n Granula ti on has b een di scussed i n § 1 1 9 Th er e

, . .

i s no questi on that the angular grai ns of crush ed m atte roast m ore readi ly tha n
th e ro und ed p ell ets o btai ned fro mgranulati on ; the d i fference however d i m in , ,

i shes wi th the si ze of par ti cles so th at wi th p ellets of % 6 i n di am , eter i t c eases .

to be no ti ceable But i n granulati ng a considerable porti on of the pellets i s

.
,

larger than 6 i n a n d t h es e ar e. i m
, p e rf ec t ly ro a st ed M a ny sm el t eri es pr e fe r .

to incur the heav i er exp ense of c rush i ng i n order to ob tai n a prod uc t m o re

sui tabl e for roasti ng In the charges for blast ro asti ng ore gi v en i n Tables
.
,

4 6 a n d 47 i t i s s how, n th a t th e m at te i s u s u a lly incorporated i n the ore mi x tur e .

The pri nc i ples and prac t i c e of blast roasti ng m at te alo ne m i xed wi th si li c i o us

materi al do not difi er fro mthose whi ch govern the trea tment of ore and thes e ,

have been gi ven i n 584 1 01 — .

A new depar ture has b een m ade at H erc ulaneum Mo 1

The granula t ed ,
.

matte wi th par ti cles not exceedi ng i n i n si z e i s m i xed wi th an eq ua l .

,

volume of li mestone ( dolomi te) cr ush ed to 14 i n or co ncentrator tai li ng ,

.
,

( ch a t s ) thoro, u ghly w et t ed a n d bl a st ro a st ed i n a D w i gh t L loy d m a ch ine run -

at a speed to treat i n 2 4 hr abo ut 75 to ns charge . There resul ts a product .

,

well sinter ed wi th 4 to 5 p er cent S An analysi s gave Pb

,
. Cu .
,

I nsol Si 02 FeO CaO MgO S Zn p e r c en t

1 83 Concentrati on Sm
. .

. elting of Roasted and Blast roasted M atte i n th e

Blast Furnace — In addi ng roasted m at te wi th say 5 p er cent Cu to th e charge , ,

.

of the ore blast furnace for the purpose of uti liz i ng th e FeO as basi c flux an d
produci ng a m atte wi th abo ut 1 4 p er cent Cu ther e have occurred tro ub l es .
,

fromfines Thi s has been especi ally the case i f roasted 1 4 p er c ent copp er
.
,
-
.

matte i s to be enri ched to 4 0 to 50 p er cent Cu by smel ti ng wi th sili cio us .

flux and li m estone Par ti al analyses of conc entrated m

. atte are gi ven i n

Table 9 1 A sim . ple and concl usi ve explanati on of thi s trouble has been fur

1 Pri vate notes, J uly, 1 9 1 6; E ng . Mi n . J .

, 1 91 6, CI, 94 3 .
404 ME TALLURG Y OF LE AD

wi th an ore charge The Cu content of the m

-
. atte i s li mi ted to 50 p er cent
-
.
,

as wi t h a hi gher conc entr ati on m etac Cu begi ns to separate .

A plant treati ng lead ores usually does not have sufli ci ent c0pp er beari ng -

materi al to warrant a separate matti ng blast furnace; a lead blast furnace

therefore has to serve for concentr ati on sm el ti ng to prod uc e m atte wi t h 40 to 50

p er c e nt C.u .

The si m plest way of operati ng i s to change fro more charge to matte charge - -

to work i n the usual w ay red uc i ng the volum e of ai r as the f urnace o therw

,
i se
beco m es hot at the top and to collec t lead b ul li on fromthe well unti l thi s freez es
,

or beco mes choked wi th cop pery lead Then lead bul li on and matte are col .

lected in the fore hearth wi th slag overflowi ng i n the usual way Lead bulli on
-

, .

and m atte are tap p ed i nto an i ro n tappi ng basi n ; i nto the li q ui d contents is

placed an i nverted T shap ed i ron bar wi th book or eye so as to perm

-
i t rai si ng
later of the soli di fied cake of matte by means of a tackle and moldi ng the lead , .

When the m at te on hand has b een sm el ted the f urnace i s p ut agai n on ore ,

charge The changes i n lead bulli on and matte are ascertai ned by assays As
. .

soon as the s e show norm al val ues the lead well i s opened wi t h an oil flam , e -

and loo sened dross i s raked out When the bo tto mof the channel h as been
'

reached a hot bar i s dri ven thro ugh the remai ni ng pl ug to furni sh an openi ng
,

for the lead Thi s wi ll ri se i n the channel and carry wi th i t the cop pery lead
.

sti ll r em ai ni ng i n the cr uci ble It tak es about a w eek for t he l ead w

. ell t o close -

up and afor tni gh t to rem

,
ov e completely the coppery lead fromthe cruci ble .

At so m e work s the tappi ng j acket has tw o tap holes one above the o t her The -
.

lo wer may serve for lead and matte and the upper for slag or the lower for lead ,

alone and the upper for m at te and slag .

Furnac es are also provi ded w i th a l ead tap on the si de opposi te t he well -

when matte and slag are tap ped at the front i n the usual way The lead tap : .
-

i s th en pl aced fro m3 to 8 i n belo wthe top of the cruci ble . .

I n or der to reduc e the am o unt of i nterm edi ary grad e of lead the lea d i ,

the cr uci ble i s di p p ed th ro ugh the well unti l the lower end of the channel
lai d b are Thi s i s then closed w
. i th a cl ay pl ug and ore run unti l the cruci b ,

i s abo ut filled agai n when m at t e charge i s p ut on

,
The lead reduced fro m
-
.

matte i s removed at i ntervals through the lead tap When the matte on h -
.

has been sm el ted ore ch arg e i s p ut on t he f ur nac e wi th ext r a lead i f necess:

,
-

As soon as lead b egi ns to co m e q ui ckly th e clay pl ug i n the si phon tap i s rem ,

o -

and the furnac e run i n t he us ual w ay D uri ng the m at te run so m e cor .

-

enters the l ead but b ei ng kep t sufi ci ently ho t i t does not soli di fy and sm
,
el , ,

goes on sati sfac tori ly on a bath of mushy lead In the course of 1 c .

days af ter the ore charge has been p ut on the coppery lead wi ll have
-

replaced by fresh lead fromthe ore charge -

.

At a fewpl ants the cruci ble of a cold lead blast furnace i s filled w i th
beaten brasq ue and thus changed i nto a matti ng furnace In such a case .
,

advi sabl e to have t he newbo tt o mof th e furnac e i ncli ned Thus t he di s .

between center of tuyere and slag tap i s 1 0 i n and the tap hole for m -
att e .
-

lead i s placed 8 i n lower at the opposi te end of the furnace Thi s furni shes
. .
406 ME TALLURGY OF LE A D

wi th threaded sock ets j i n test carri age k r unni ng on rai ls The two , ,
-

, , .

front screws can be ro ta ted together by a pai r of wormwheels I on shaf t m -

, , , ,

revolved by bevel wheel and pi ni on and these by hand wheel n ; i n a -

,
-

si mi lar way the tw o b ack screws can be rai sed and lo w ered fromthe si de by -

t urni ng a crank ( not shown) The steel water j acket i t recei ves i ts cooli ng .
-

, ,

water at the back (not shown) and i s drawn 06 at the front fromthe top ,

through pi pes o and o the cast i ron breast j ack et h rec ei ves i ts w
'
ater at p
'
- -

, , ,

and di scharges t hro ugh t w o pi pes q and q ; thus the j ack ets are al w ays fill ed
’
,

wi th water Rubber hose connects the j ackets wi th the supply and di scharge
.

pi pes The hearth materi al i s a m

. i xt ure of rawand burnt clay or of rawclay
and q uar tz A chrom i te li ni ng or better one of chrom
1
. e bri ck l asts a long , , ,

ti me .

The fire box has h ki ng grate worked wi th underwi nd On ei ther si de

-
a s a ,
.

of the bri dge i s a tuyere pi pe thro ugh whi ch blast enters upo n the hear th Th e -
.

f urnace i s i ncased i n i ron plates and i s st rongly bo und wi th i ron rods It wi ll .

bri ng fo rward i n 3 days abo ut 1 0 tons of 40 p er cent copper matte to bli ster -
.

copper the mat te bei ng charged i n four por ti o ns first 4 5 per c ent then 2 5 p er
, ,
.
,

cent 2 2 per cent and 8 p er cent The 1 0 tons of matte produc e 8700 lb
.
, .
,
. .

bli ster c0p p er wi th 9 5 p er cent Cu and 8300 lb of slag assayi ng p er c e n t . . .

Cu and p er c e n t P b an d r eq ui r e 9 00 g al of r ed u c ed o il wi t h ai r as at.o m ,
.

i zer The furnace i s well adap ted for concentrati ng retor t b ul li on i f the h ear th
.

is m ade thi nner and shallo w er .

A sp eci al m od e of operati ng i s the one of Frei berg Saxony where m 1

a t te , ,

wi th 50 p er cent Cu i s roasted i n a hand reverberatory furnace and then

1
.

t reated i n a sm el t i ng r ever ber atory wi t h bar i te and q uar tz as fl uxes T he .

hear th of the furnace i s 1 3 ft long 4 ft 2 i n wi de at the bri dge 8 ft at the .

,
. .
, .

mi ddl e and 1 ft 2 i n at the flue; the grate 4 ft 3 i n by 3 ft 4 i n i s 1 ft

, . .
, . . . .
, .

3 i n b elow
. th e t op of t he bri d g e w hi ch i s 1 ft 3 i n b elow th e roof Th e ,
. . .

f urnace has two doors one at the si de and one beneath the flue The bo tt om ,
.
,

whi ch i s b ui l t on an i ron plate consi sts first of a full course of fire bri ck on whi ch ,
-

i s ram med firmly a mi xture of fire clay and quartz gi vi ng i t the usual di sh li ke -

,
-

for m wi th the lowest poi nt at the tap hole The thi nnest part of thi s l ayer
,
-
.

i s 3 i n t hi ck The worki ng bottom whi ch follows consi sts of 5500 lb of an

. .
, , .

i nti m ate m i xture of 5 par ts of q uartz and 1 par t of m atte slag It i s m el ted -
.

do wn aft er bei ng heated and patted i nto shape i n 1 2 hr and lasts fro m1 5
, , .
,

to 1 8 m onths Fi ve charges each wei ghi ng 4 2 90 1b and consi sti ng of 2 640 lb

.
,
.
, .

roast ed matte 44 0 lb rawmatte 660 lb bari te and 550 1b q uartz are treated
,
.
,
.
,
.
,

i n thi s f urnac e i n 2 4 hr 4 14 t ons of bi tum i no us coal bei ng consum ed From .

, .

th ese five charges 8 2 50 lb of m atte i s produced The co m posi ti on of m at te . .

and sl ag as analyzed by Schert el i s gi ven i n Table 93 :

1

1
Lang , E ng Mi n J. . .
, 1 89 7, m
an , 2 07 .

1
Grand, Ann M i n . .
, 18 75, vn , 3 1 4 .

Cap acci , Rev Uni v . . M i n , 1 88 1 , D1 ,

. 2 69 .

1
Schertel, B erg H rtttenrn Z .
‘

. .
,
1 888, X LVII , 44 2 .

1
Loc ci t . .
 S MELTI NG L E AD ORE S I N TH E BLAS T F UR N A CE

TAB LE 93
— AN ALYS E S. or MArrE ' '
AND SLAG FRE IBE RG Conca maA rron SME LTI N G

Matte
O O O O O O O O O O O O O O O O O O O O O O O O O

O O O O O O O O O O O O O O O O O O O O O O O O O

O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O

O O O O O O O O O O O O O O O O

O O O O O O O O O O O O O O O O O O O O O

O O O O O O O O O O O O O O O O O

In order to obtai n m at te r unni ng so low i n i ro n i t i s necessary to prod uce ,

so m e bo tt om s These go b ack to the next reverberato ry charge or are added

.

t o the last blast furnace ch arge to be agai n co nverted i nto m atte The m atte .

for ms the rawmateri al for t he manufac t ure of bl ue vi tri ol .

The behavi or of BaSO, has been treated i n § 1 4 3 Schwed er found i n hi s

1
.

experi m ents th at CaSO , and N a3804 behaved si m i larly to BaSO4 .

Another m ethod of bri ngi ng forw ard m atte wi th 40 p er c ent Cu to bli ster .

copper i s the one i n operati o n at H oboken les Anvers pat ented by C H eberlei n 1 - -

, .

where the bl ast furnace ma tte i s blast roasted i n a H unti ngton H eberlei n -

p o t w i t h th e a d di ti on of li me st o ne and q uar tzi te and the produc t sm e l t ed in ,

the r everber at ory f urnace for b lis ter copper D uri ng the blast roast a large .

par t of the As and Sb i s volatili zed .

Laboratory exp eri m ents by H esse

1
and Menzel
1
th row li gh t upon t he
chem i cal behavi or of m at te com ponents and fl uxes when subj ec ted to elevated
tem peratures i n carbon and elec tri c furnaces .

1 85 Converting of Lead Capp er Matte, General

.
L —In thi s process whi ch i s -
.
,

the l at est i m provement i n the treatment of lead copper mattes ai r i s forced i n -

sm all st ream s t hro ugh one si de of an i ron vessel li ned wi th refrac tory m ateri al , ,

i nto m ol ten mat te hel d at a temperatur e of 1 1 00 to 1 2 00 C wi th the obj ec t °

.
,

oxi di zi ng Fe Pb and S and recoveri ng Cu as m ,

etal The oxi di zed Fe i s
, ,
.

sl agged ; the o xi di zed Pb i s i n part sl agg ed i n par t volati li zed ; the 5 form s so. ,

and passes ofl Slagged Fe and Pb are subsequently retr eated i n the blast
.

furnace as i s the volati li zed Pb

,
.

The first successf ul converti ng of concentrated lead copper m at te was that at -

Aguas Cali entes early i n 1 900 usi ng an upri gh t aci d li ned vessel The i d ea held -
.

1
B erg H i ttten . mZ . .
,
1 8 79, xxxv m 38
,
.

1
M etallurgie, 1 9 1 0 v n 2 85 , , .

1
M etallurgi e 1 9 1 1 v m3 2 1 , , , .

1
M atoll u E ra 1 9 1 3 x 1 93 . .
, , , , 2 30 ; E ng . Mi n . J .
, 191 3 , xcv, 90 2 ; Abhandlungen I nsti t .

M ctallkrtttenwcsen n
’

Electro mt lturgi c a 1 9 1 5, 11 , he t f 1 .

m m5
.
,

1
Vail E ng M i n , . . J .
,
1 9 1 0, ,
03 .

Moore op ci t ,
. .
, 1 9 1 0, xc, 2 63 .

Kuchs, Tr A I M E . . . . .
, 1 9 1 4 , x u x, 5 79 .
408 ME TALLURGY OF LE AD

previ o usly that the losses i n Ag were enormo us was based on a m

1
i si nterprets
ti on of data co m i ng fromA Rah t who held that i dea abo ut 1 89 but w as .

convi nced later on of the contrary when he fo und that true fume fro mthe
1
,

co nver ter assayed o nly 2 oz Ag p er ton and that the loss i n Ag was propor .
,

ti onal to th at of Cu ; i n o ther wor ds t hat the loss w as a m ech ani c al and not a ,

volati li zati on loss Thi s fact i s bro ught out by the later data of Aguas Cali
.

s gi ven by Sem ple and shown i n Table 94 The converters are upri ght
1
ente .

( di am e t er 8 f t ; h e
,
i gh t fro m t uy er.e to b ase of hood 7 f t 4 i n ; bl a st pr essu r e ,
. .
-

1 2 1 6 so m eti m es 1 8 lb h ho d d i l fl h vi g
— t
, p er s q e o s en n a stee u e a . n .

di scharge doors for dust ; t he gases pass fro mthe flue to an exhaust fan whi ch
-

forces themthro ugh fo ur bri ck sec ti ons a c urtai ned chamber and four steel , ,

cooli ng flues i nto the bag house .

T AB LE 94
— AN ALY SE S
. or CO NVE RTE R FU ME rnou AcuAs CALIE NTE S

At throat of converter .

Converter flue dust -

Oval p i pe ho pper
Fan house, secti on 1 .

Fan house, secti on 2 .

Fan house, secti on 3 .

Fan house, secti on 4 .

Curtai n cha mber

Condenser
Bag house 1

Bag house header .

T he ccess at Aguas Cali entes led to the i ntrod uc ti on of the aci d li ned
su -

upri gh t v essel at Om ah a N eb i n 1 905 Thi s w as 7 by 1 4 ft at the star t i t w as ,

.
, . .
,

ch arg ed wi th 3 to ns of 4 0 p er c ent m atte i n two or three successi ve addi t i o ns -

.
, ,

and blown to bli ster copper am o unti ngto 2 500 lb The second m at te charge ,
.
-

gave 5000 lb cop per th e th i rd . and the four th lb wh en th e

, .
,

co nverter had to be reli ned The aci d vessel was supp lemented in 1 908 by .

one wi th a b asi c li ni ng Th ere were i n operati on i n 1 9 1 2 tw

1
o upri gh t a ci d and
.

one hori z ontal b asi c ( Pei rc e Sm i th) converters As i n conver ti ng lead COp p er -
.
-

matte th e basi c vessel has the same great advantages over the aci d as i n convert
,

i ng lead free copper i ro n m

-
at te
“ basi c vessels have enti rely replaced the acid
-

, .

Peters , E D , Modern Copp er Sm

1 “ elti ng, M cGrawH ill Book Co , 1 89 5, p 569
-
. . . . .

1
H am i lton, Tr A I M E , 1 9 1 3, X LVI , 4 75. . . . . .

1
Pri vate co mmuni cati o n, M arch 4, 191 1 .

1
E ng . Mi n . J .
, 1 9 1 1 , X CI , 508 .

1
E ilers, Tr A I . . . M . E .
, 1 9 1 2 , x u v, 708 .

1
H of mn a ,
M etallurgy of Cop per ,
”
1 9 1 8, p 334 . .
4 10 ME TALLURGY OF LEAD

of the cylinder also i a steel are not firm

,
ly connec ted but have flanges
of -
.
, ,

whi ch ex tend i nto the cyli nder in order th at the heads may yi eld to the longi
tudinal thrust of th e exp and ing lining They are back ed by I beam s wh i ch are .
-

ti ed by bol ts and nuts to the cast steel annular tr ead s at the end s Of the cyli nd er -
.

A bol t passes thro ugh the annular t read and a pi ece of flat i ron whi ch bears -

upon the I b eam and i s lock ed wi th a nut

-

,
Loo sening of nuts furnish es the .

sp ace necessary for expansi on when the furnac e i s b ei ng heated ; bendi ng of the

flat i ron i ndi ca tes the strai n p ut upon the bolt

-
.

The cyli nd er has 4 16 in bene s th the m ed ian horiz o ntal p lane 2 0 cast iron.
-

t uy eres 2 in sq uare wi th i ho les wh i ch ex tend thro ugh the li ni ng and

‘

, 5. n ,
-
.

have a downward pi tch The pi pes are provi ded wi th Dybli e valves and are .
1

connec ted by wi red hose to a wro ugh t i ro n blast pipe bol ted to the cylinder - -
.

The blast pi p e i s connec ted by a cast i ro n p i pe and swi ng joi nt wi th the m

-
ai n of - -

the blowi ng engi ne -

.

FI GS .
398 to 4 00 — S i th dev
.i ce for repai m
ri ng t uyere belt -
.

Si nce in conver ti ng lead COpp er atte, the tuy ere zone, 9 i n abo ve and below -
m -
.

the tuy e re pi pes, i s lik ely to be q ui ck ly corrod ed, the shell i s provi ded th ere
-

m
wi th ovable plates The S i th d evi ce for repai ri ng the tuyere bel t i s sho wn
.
1
m -

i n Fi g s 398 400
. The shell has o blong openi ngs wh i ch are closed i n par t by
—
.

m ovable p lates, A bolted on through ovable strap s ; these are secured so as to m

l ea ve roo mfor the plates B whi ch are i nserted and k eyed The plates are , ,
.

fork ed at the lower ends that they maypass ov er the pro trudi ng cast i ron tuy eres -
.

Op p o si te the tuy eres on the breast or po uri ng si de i s the po uri ng Openi ng

, ,

wi th spo ut The lower par t i s clo sed wi th a m

. agnesi te bri ck prov i d ed wi th tap

hole for casti ng bli ster copper ; the upper wi th clay mwhi ch 13 left an Openi ng
1
H of man , Metallurgy of Copper ,
1 91 8, p 306 . .

1 9 , 1 9 1 2 ; E ng Mi n J
1
U S Patent No
. . . 1 044 58 7, N OV . . . .
, 1 9 1 3, x cv, 32 2 .
 S M E LTI NG LE AD ORE S I N TH E BLAS T F URN A CE

of abo ut 3 i n in di am eter for pouri ng slag wh i ch i s collec ted i n a ladle or m

. ay be ,

granula ted as shown i n Fi g 394 . .

I n one end of the vessel i s an openi ng for i ntrod ucing an oi l b urner used for -

warming and h eati ng a newconverter or for keepi ng i t hot when temporari ly ,

o ut of co m missi on .

In the center of th e top i s the thro at for recei ving charges and deli veri ng
gases to a li ned hood leadi ng i nto a dust chamb er whence they p ass to the ,

co ndensi ng ap paratus for collec ti ng fumes The di stance between the o uter .

di am eter of th e no se of th e co nver ter and th e i nner di am eter of the hood i s

abo ut 8 i n i n ord er that sufi ci ent space m

.
,
ay be provi d ed for ai r to ent er and

cool the gases .

The conver ter i s ro tated Fi g 396 by m eans of tw o wi r e ropes of wh i ch one

, .
, ,

end i s at tach ed to the conver ter the o th er to block s sli di ng i n gui d es di rec t ,

connec ted wi th the p i ston rod of the hydrauli c cyli nder -

.

The l ini ng is m ai nly m agnesi te bri ck In order to save in co st of construo .

ti on th er e i s plac ed on th e bo ttoma course and a h alf of fire bri ck along the

,
-

center li ne; th e thi ckness of 1 3 i n tapers on one si de to a full co urse at 8 i n below . .

th e tuy e re lev el and to a half co urse on the o ther The worki ng li ning i s 9 i n
-

,
-
.
-
.

thi ck excep t at th e tuy e res wh ere i t is 1 8 i n The oval cavi ty has a length ,
.

of 1 1 ft 4 i n and a width of 7 ft at the medi an cro ss li ne The magnesi te

. . .
-
.

bri ck are lai d dry w i th th e spaces filled i n w i th m agnesi te po w der ; at th e

tuy e re b el t a mor tar of magnesi te powder and li nseed oi l i s used In order to
-
.

f urni sh roomfor expansi on pi ne sh ingles M i n th i ck are i ntroduced af ter , ,

.
,

every ei gh th co urse of 9 i n bri ck -

. .

Followi ng the exam p l e of M a th ew s o n at A n aco nd a

1
th e ca st i ro n of th e

t uyere pi pes has b een replaced i n so m

-
e i nstances by wro ught i ron and t he ,

li ni ng of magnesi te bri ck at the tuyere bel t by rammi ng i n place 8 i n above -

, .

and b elow the tuye res a mass consi sti ng of finely gro und magnesi te , ,

asb esto s and 2 0 p er cent of a 4 0 p er c ent sol uti o n of sodi umsi li cate
,
.
-
. .

The blast pressure req ui red i s about 1 5 lb p er sq i n ; 1 8 t uyeres 5 i n . . .

,
.

i n di am eter are used the tw o end tuye

,
res b ei ng closed ,
-
.

The acc essori es are si m i lar to those used i n conver ti ng copper m att e
1

excep ti ng th at t he slag m ay be granulated i nstead of bei ng c ast and the

casti ng of copper i s usually more si m

,

ple on acco unt of the smaller amo unts

pro duc ed .

T he m atte rec ei v ed fro mthe fore h ear th of the blast f urnace i s usually
,
-

stored i n a reverb eratory f urnac e si m i lar t o the one shown i n Fi gs 2 52 and ,

.

2 54 ,
whence i t i s tapped i nto a ladl e holdi ng 6 or more tons and poured i nto ,

the co nver ter I t can be m el ted i n the conver ter but thi s i s excep ti onal
.
,
.

The si li c i ous ore crushed to 95 i n and frequently w ,

arm ed i n a m echani cal .

reverb eratory i s rai sed i n sui table amo unts i n a sheet i ron box or boat and sho t
,
-

i nto the convert er

1 87 Process and Mani pulafiom The proc ess and m
.

.
— ode of operati ng are
1
H of man ,
“Metallur
gy of Cop per,
”
1 9 1 8, p .
34 5 .

1
I bid , p 3 1 4 . .
4 12 ME TALL URC Y OF LE AD

the sa m as e co v r ting copp ron m

in n e atte i n so far as the pri nci p les i nvolved
er i -

are co nc erned ; they di fl er however as to detail , , .

A co nver ter i s w ar m ed i n abo ut 3 or 4 days by firi ng w i t h cord wood and ,

th en bro ugh t to the d esi red converti ng tem perature i n about 8 hr by means .

of an oil fla me or i n abo ut 4 hr by b urni ng 1 ton of coke The hot converter

,
. .

recei ves 20 to ns of li qui d matte ( Cu 4 6 Pb 1 7 Fe 1 2 S 1 9 Ni Zn As etc , , , , , , ,

.

4 p e r c e n t ) a.nd t h en 1 to n of w ar m ed si li c i o u s o re ; bl ast of a bo ut 5 lb pressure .

i s adm i tted ; t he conver ter i s t urned sufi ci entlyto bury th e t uyeres i n the m at te ,

when the bubbli ng of the bath wi ll cause the ore to spread ; i t i s th en turned
over farther that the tuyeres may be 2 4 i n b elo wthe surface of the matte .
,

whi ch req ui res i ncrease of vol ume of ai r that i ts pressure may ri se to 1 5 lb The .

blowi ng on matte for whi te metal lasts about 30 mi n It represents the sl ag .

g i ng st a g e i n wh i ch Fe P b a nd S a re o
,
x i d i ze d ; th e,
F eO a n d P h o as soo n a s ,

formed co mbi ne wi th the si li ci ous ore and formslag The rate of scori ficati on
,
.

of the ore i s recogni zed by the fl ui di ty of the slag Thi s i s tested by q ui ckly .

i nserti ng an i ro n rod i nto the boi li ng bath through t he slag po uri ng openi ng and -

wi thdrawi ng i t The rod o ugh t to pass readi ly through the slag and o ught to
.

be covered when wi thdrawn wi th a uni for mcoati ng of slag free fromunm

, , el ted

parti cles A lack of flux or a low temperature or an i nsufi ci ency of ti me of

.
, ,

blowi ng tend to forma mushy slag When the ore—charge has been sati sfac .

tori ly slagged the slag i s po ur ed and 1 0 tons of m

,
at te are po ured i nto the vessel
, .

The co nver ter i s ri gh ted so th at the tuyeres becom e uncovered t he b last i s ,

sh ut off and abo ut 1 000 lb ore sho t i n

,
The blast i s agai n adm
. i t ted th e .
,

converter turned over as befor e and blowi ng co nti nued for abo ut 2 0 m , in Th e .

operati ons are conti nued fo ur i n all wi th decreasi ng amounts of m

, at te and ore ,

unti l the conver ter holds from2 8 to 30 tons whi te m etal whi ch reach es w i th ,

the ri gh ted conver ter to about 3 i n b elo wthe t uyere l evel .

-
.

The rate at whi ch Fe and Pb are scori fied and the S i s oxi di zed i s si m i lar , ,

to that i n worki ng copper i ro n m at te

1 -
.

There follows the bli ster form i ng stage i n w hi ch the 2 8 to 30 t ons whi t e metal
-

are blown i n ro ughl y 1 hr t o abo ut 2 5 t ons of bli ster c0pp er whi ch assays Cu
,
.
,

9 94
2 —
, A g 1 i P b 1 ,
2 A s 1 Sb
-

N i et c ,4 p er c e n t T he,
co nv ert er i s turn ,
ed . .

over and blown but wi tho ut ore The Cq i s oxi di zed to C030; thi s reac ts
,
.

upo n sti ll undeco m posed Cq and gi ves Cu and $ 02 as i s shown by cu, s , ,

som e CugO enters the sm all

am ount of slag formed or i t remai ns unco mbi ned i n the vessel

,
.

A po ur of 2 5 t ons bli ster copper i s ob tai ned by blowi ng 50 to ns 50 p er cen t -

.

matte for about 6 hr of whi ch 2 hr are taken up by handli ng materi als

.
,
. .

The progress of a blo wi s watched m ai nly by the f um e passi ng 03 at th e

thro at of the vessel ; the color of the fl am e form s no sati sfac tory ui de as i t i s
g ,

obsc ured by the fume and vi ti ated by the i mp uri ti es of the matte The end .

of a blow i s ascertai ned by the color of the slag whi ch sho uld not be reddi sh , ,

and by punch i ng a tuye re and q ui ckly wi thdrawi ng the bar Thi s should be .

1
H of man , Cop per, p 3 2
. 6 .
4 14 M E TALLURGY OF LE AD

at bag ho use ,
at sta ck 58 ,
°
C ; the te
. mperature i n the bag house
vari ed fro m37 to °
and averaged
°
60 C .

Determ i nati o ns of SO, and SO; i n the gases are gi ven i n Table 95 .

T AB LE 9 5 . and Soa CO NTE NT

-
or CO NVE RTE R -
G AS

80 , content ,
-

p er cent . SOs content, p er cent

-
.

I n bag house

W i th vac uumat the conver ter of

a i n water at the fan of i n the .
,
.
,

pressure i n the cellar i s 0 56 i n and hi gher reachi ng 1 to 2 i n i n the bags ; w

. . i th a ,
.

vacuumoutsi de of the bags as lowas i n that at the base of the stack is .

in .

The matte blown average s: Pb Cu Ni Co Fe Zn

S As Sb Si O, p er cent .
,
and Au Ag oz .
p er ton .

The blo w gi ne f urni shes 5800 cu ft ai r p er m

i ng en i n at a pressure of 1 7 lb . . . .

p er sq i n W i
. th a.d ai ly o ut p ut of 45 t o ns b li st er c0pp er fro mm at te wi th P b 23 ,

Cu 4 5 S 1 8 per cent there are prod uced 1 6 to ns of bag house f um

, . e w i th Pb
Zn Sb Te Se com bi ned SO; free SO , p er

cent and Ag
.
, oz p er ton The com . po si ti on of the d ust collec ted i n the
.

flues i s gi ven i n p art i n Table 96 .

T AB LE — D US T CO N VE RTE R FLUE
96 . or

The data show a general fall of Ag and ri se of Pb content wi th increase of -

di stance fromconver ter to bag ho use and a red uc ti on of free SO ; whi ch di s ,

ap pear s at 800 ft fro mthe co nver ter

. I t bri ngs o ut the i mpor tant i nfluence .

the p resenc e of lead f ume has upo n th e neutral iza ti on of free 803 The gases .

fro mmat te contai ning less than 1 4 p er cent Pb canno t be fil tered wi thout .

the adm ixture of o ther neutrali zing ag ents such as CaO or ZnO as in the
Sp rague p rocess
 S MELTI NG LE AD ORE S I N TH E BLAS T F URN A CE

In the first at te mp t to fil ter converter gases at Maurer , the bags were

corroded in 30 mi n d uri ng the finishi ng blow for bli ster Cop p er when the Pb .
,

co ntent of the mat tehad been red uced to 2 p ercent The throat of the conver ter .

had b een fi t ted c losely into the bri ck flue leading to the bag ho use T he tem .

ack of the conver ter ranged from4 2 6 to 704 C and at the

° °
p era tu re of th e fl u e b .

op p osi te end fro m2 04 to th us covering a rang e well sui ted to co nvert

°

S03 i nto S03 w hen the SO ; not com b ined wi th Pho attacked the filteri ng
,

fabri c Reduc ti on of temper ature to a maxi mumof 3 1 5 C i n the bri ck flue

.
°
.

2 5 ft fro mthe co nv er ter and di m

. i nuti on of th e SO s co ntent of the gases from ,
-

as m uch as 9 p er c ent vol to 4 p er cent corrected the evi l to such an ex tent th at . . .

,

even co t to n b ags lasted over 1 y ear It w as accom pli sh ed by enlargi ng the .

,

bri ck flue Opposi te the conver ter so that ai r would enter wi th the sulp huro us
g a s by a
, d a m p e red por t i n t h e fl ue thro u gh wh i ch a dd i ti o nal ai r co uld b e dr a w n
i n and by sp eedi ng up the fan
,
.

The Co ttrell proc ess for the cond ensati on Of conver ter fum e w as first i ntro

duced at the copper sm eltery of Garfield U ta h by H o w ard

1
and has si nc e been , , ,

i nstalled at o th er p lants .

A disc ussi o n of the p roc ess i s g i ven i n § 2 1 4 .

The m a t te prod uced at Garfield i n the blast furnac e co ntains fro m 2 0 to

4 p0 e r c en t C u th a t in th e r e v e
. rb era tory fu rna c,e fro m 33 to 8
4 p er c ent ; .

and m ore or less Pb besi de the usual amounts of Fe and S I t i s b lown i n .

basi c li ned Peirce Smi th conver ters ( cyli nders 2 4 ft long and 1 0 ft in
- -
. .

diam eter ) wi t h a pressure of 1 0 lb p er sq i n thro ugh 3 7 tuy e r es i n in . . . .

di am eter pl ac ed 1 8 i n abov e the bo tto m The co nst ruc ti o n of the or i g i nal

,
. .

co nver ter has b een changed in order to reduce the amo unt of ai r enteri ng the
11

flue wi th th e conver ter gas and thus to d i m ini sh the vol um e of d i luted gas ,

whi ch i s to pass thro ugh the elec tri c preci p i tator .

Th ere are i n Op erati on sev en conver ters wh i ch furni sh p er m in .

cu ft gas at flue tem

. . p erature equal to about one half thi s volume at standard ,
-

condi ti ons The gas travels thro ugh an elevated balloo n flue 1 000 ft long
.
,
.

a nd 2 1 0 sq ft i n cro ss sec ti o n at a sp eed of abo ut 1 2 ft p er sec

. . Most of the
-

,
. .

°
Cu beari ng d ust settles i n the flue; the gas i s cooled to about 90 C b efore i t
-
.

enters the el ec tri c t reater Thi s i s show n i n Fi g s 40 1 4 03

—
I t co ntai ns seven . . .

uni ts one for a conver ter ; g enerally si x are i n Op erati o n and one i s bei ng c leaned
, ,

or rep aired A uni t has 360 gro unded ver ti ca l ca st i ron p i p es 5 i n i n di ameter
.
-

, .

and 1 0 ft lo ng serv ing as p reci p i tat i ng elec trod es

.
,
I n the c enter of each i s .

h eld taut a steel wi re of No 1 4 gauge wh i ch servi ng as di scharge elec trode .

, ,

i s connec ted w i th the interm i t tent di rec t c urrent of volts There i s .

,

th er efore m ai ntained i n each p i p e an elec tri cally ch arged field thro ugh wh i ch
,
°
the gases cool ed to b elow 1 00 C trav el and d ep osi t on the p i pes all d ust
,
.
, ,

fume and moi sture The depo si t whi ch do es not drop off i s loosened by
,
.
, ,

k nock ers at i ntervals i nto the lower gas chamb er provi d ed wi th openings , ,

1
Al exander, Tr A I . . . M . E .
, 1 9 1 4, x mx , 56 1 .

1
Tr A I . . M . E . 1 9 1 4 , x ux , 540 .

m9
.
,

1
M at ChemE ng . . .
,
191 5, x , 24 .
4 16 ME TALLURC Y OF LE AD

closed by gates to rem

, ove the d ust . wires have si m
The discharg e -
i lar knockers
to d etach adh er ing p ar ti cles of fum e The gases. in whi ch the rati o of ,

SO ; 2803 i s are adm i tted fro mthe co nver ter flue to a uni t thro ugh three

F1 0 4 0 1 — Lon i tudi nal

elevat i on
. .
g .

Cottrell p lant, Garfield, U tah .

FI G 4 0 2
. .
— Cross
sect i on .

Cot trell p lant, Garfield, U tah .

i e
p p ,
s provi ded wi th damp ers i nto the lower gas ch amber Th is has three
,
.

comp ar tments in order to at tai n an even di stri buti on of gas E ach pipe has .

a gable shap ed roo f wh i ch serv es a si m

-
i lar p urpo se The t reated gas of a
.
4 18 ME TALLURGY
'
OF L E AD
 S MELTI NG LE AD ORE S I N TH E BLAS T F URN ACE 4 19

deposi ted I t m ay be recall ed that SO; bo il s at 4 6 C ; that 11 2504 of 60 B 6

.
°
.
°
.

i s vapori zed at 2 00 C and An g at 1 4 3 C 1 ° °

. .
,

1 89 Converting Lead Copper Matte W i thout Addi ti on of Flux ; Tooel e

.
-

Utah .
1—
~
Thi s method of co nv er ting had i ts ori g in at Too ele U tah The basi c , .

li ned barrel conver ter i s shown i n si de and end elevati ons i n Fi gs 404 and 405 -
.
,

and i n long i tudi nal and transverse sec ti ons i n Fi g s 4 06 and 4 0 7 The barrel . .
,

6 by 1 50 i n co ns i sts of th e usual two p ar ts the bo il er i ron sh ell and hood

9
-

,
.
, ,

whi ch are jo i ned by k ey bol ts I t rests wi th steel runners on two p ai rs of -

.

fri c ti on rollers ca rri ed by a roll er stand At one end i t has a trunni on whi ch -
.

carri es a sp ur wheel dr i ven by a p ini on the shaf t of wh i ch carr i es at the Op po si te

-

end a wormwh eel engag i ng wi th a wormattach ed to the sh af t O f an elec t ri c

-

FI G 4 06 — Longi tudi nal secti on FI G — Cross secti on

. . . .
40 7 . .

Basi c barrel converter, Tooele, U tah, 96 X 1 50 i nches .

mo tor . At the o th er connec ti on i s made wi th the blast p i p e whi ch d eli ver s

end, -

th e ai r fromth e b lowi ng eng ine thro ugh 1 6 1 2 i n tuye res The shell i s li ned
- -
. .

wi th standard m agnesi te bri ck back ed by crushed bri ck filling The th i ckness -

.

of the li ning on the tuyere si de of 2 0 i n and on the ends of 2 2 i n i s in -

.
, .
,

st r i k i ng cont rast w i th that on the bo tto mand the si de opp o si te the tuy eres ,

wh i ch i s 4 16 i n .

1 90 Process and Mani pulati on

.
— In blowi ng lead COpp er i ron m at te the - -

metalli c sulph i des are oxi dized but n ot scorified o w i ng to the ab sence of Si 02 , , .

O xi d es of lead and zi nc are volati li z ed and coll ected i n a bag ho use; oxi des of
cop per and i ron and some metalli c copper forma flui d mass are poured i nto a ,

l adle and t ransferred to a conver ter trea ti ng lead fr ee copp er i ron m

, at te wi th - -

si li ci o us ore i n the usual m anner j ust af ter thi s has recei v ed i ts ch arg e The .

oxi des of copp er are sulphuri z ed the i ron o xi des scorified and the metalli c , ,

c0p p er tak en u by the m at t

p e .

1
Elt on Tr A I M E 1 9 1 3 X LVI 690
, . . . . .
, , , .

1
Knobs, Tr A I M E , 1 9 1 4 ,
. . . . . x ux , 579 .

s , J uly, 1 9 1 6
Pri vate note .
420 M E TALLURGY ’
OF LE AD

The advantages of the process over the one usi ng si li ci ous flux are, t at ve h ry
li ttle Pb bea ri ng slag i s formed whi ch would have to be smel ted i n th e lead
-

blast furnace ( i n the ordi nary proc ess 4 5 p er cent of the Pb i n the ma t t e i s .

slagg ed) ; and th at on account of the larg e am , ount of Pb and Zn fume fo rmed -

there i s p resent i n the gases very li t tle free SO . to corrode the woolen ba gs ;
i n fac t 50 p er cent of the Zn i n the m
,
att e passes 03 wi th the gases as aga i ns t
.
,

1 0 p er cent wh en si li c i o us ore i s used

. .

The plant shown i n Fi g 408 has five conver ter stands of whi ch three trea t
,
.
, ,

lead Cop p er i ron mat te and two copper i ron matte The gases fromlead ma t te
- -

,
-
.

conver ters are drawn by a N O 2 0 Si rocco fan ( capaci ty cu ft ga s p er

. . .

mi n ) through a hopper bo tto msteel flue provi ded wi th i nlet for cold ai r to
.
-

red uce the temperat ure to 1 00 to 1 1 0 C and deli vered i nto a bri ck flue wi th ° °
.
,

“M ar k

FI G — Convert er fines and

.
4 08 . bagho use, Tooele, U tah .

branch es lead i ng i nto the bag ho use; th i s has 960 woolen bags 1 8 i n i n diameter ,
.

and 30 ft lo ng w i th 2 4 threads to the i nch

.
1
The gases fro mthe Cop p er m a t te . -

conver ters p ass thro ugh a steel flue to a stack 1 6 ft i n di ameter and 1 5 0 ft . .

i n h ei gh t .

In blo w i ng l ead m at te a large vol um e of dense f um

, es i s evolved at fi rst ;

the f um es di m i ni sh when the blow i s about half fini shed and di sap p ear ,

gradually At the same ti me the flame becomes mo re and more Vi si b le ;

.

when plai nly vi si ble the wei gh t of the mat te has been red uced to 60 t o 70
,

p er c ent of th e
. or i gi nal ch arg e ; t he m a t t e r et ai ni ng 1 to 1 5 p er c ent Pb . .

A co nverter rec ei ves 9 tons m

.

at te i s blo w n 2 hr w i t h a pressure of 1 2 t o 1 3
,
.

lb the t uyeres have to be p unched freq u ently The ti m e bet w een blo w s is .

14 hr . O ne sk i m m e r at t end s t hre e co nv e r t e r s o n e p u n ch er a nd helper are re ,

q ui red for every vessel The converter i s patched by pouri ng i nto the wea k
.

—
ened li ni ng Pb beari ng conver ter sl ag to the r eq ui red t hi ck ness whi ch is ,

allow ed to co m e to a set i n 1 5 to 2 hr At the t uyere bel t closed i ron pi pes are

. .
-

i nser ted and slag po ured aro und them

,
.

The eli m i nati on of Pb and Fe i s qui ck at first and l ess so t oward t he end
of a blo w; the oxi dati on of Zn i s slo wand more uni formthan that of th e o t h er
components The temperature i n the vessel i s not allowed to exceed 930 C
.
°
.

1 In a newi nstallati on th
e flues w ould be m ade larger and l onger .
4 22 ME TALLURGY OF LE AD

TAB LE 97
— RAW MATE RIALS
. AND PRODUCTS or CO NVE E TING , TOO E LE , UTAH

Blowof Lead beari ng Copper Iron - -

Matte

Blowof Lead -
free Copper Iron M atte -

Lead free matte-

Converter slag 23 4

1
Ounces p er ton .

cti on of the bag house and the suspensi on and shaki ng devi ces of
A
‘

se

the bags are shown i n Fi gs 4 1 0 4 1 5 The bag house bui l t of bri ck i s 1 2 5 ft 6

.
-
.
, , .

i n by 4 7 ft 6 i n outsi de and 50 ft hi gh to the eaves

. . .
, I t i s di vi ded by a sheet . .

steel thi m ble floor i nto the filter cham

-
ber above and the cellar space below - -
.

There are ei ght hopper bo t to mcellars 1 3 ft 716 i n hi gh ; si x are 1 3 ft 1 1 i n

-

,
. . . .

by 44 ft and the two end cellars are 1 5 ft 5 i n by 44 ft The fil ter cham

.
,
-
ber has . . .
-

9 60 w ool en b ag s or 1 2 0 t o a c ell,ar 1 8 i n i n di a m ete r a nd 3 0 ft l o ng A ba g

,
i s . . .

suspend ed froma 2 3 4 i n i ro n p i p e by -
a N o 8 sof
. t st e e l w i re wh i ch p asses .
-

t hro ugh a M i n pi pe 4 i n long form

-
. i ng a loop ; the upper end of the bag i s
.

gath ered turned over the shor t pi pe and ti ed E ach cellar i s connected wi th the
, ,
.

mai n gas flue and the reverse c urrent gas flue by means of ports to be closed by -

valves The gases fro mthe conver ters arri ve i n the mai n gas flue enter th e
.
,

cell ars pass thro ugh the thi mble floor openi ngs i nto the bags leave the filter
,
-

chamber at the top through a flue endi ng i n a bri ck down take whi ch leads -

to a b ri ck st ack 1 5 by 1 50 ft , D uri ng thi s ti m e the por ts i n the reverse c urr ent

.
-

g as flu e ar e clo se d W h en t h e d u s.t i ns i d e the b ag s of a c e ll a r i s to b e d i slodg ed ,

the port i n the m ai n gas flue i s clo sed and that i n the return flue (joi ned to a -

No 416 Si rocco fan whi ch deli vers i nto the m

. ai n flue) opened The pressure .

i n the bags i s thereby r epl aced by a sli gh t vacuum causi ng the bags to collap se ,

and to shak e ofl adheri ng dust By repeati ng the swelli ng and coll apsi ng of .

bags a few ti mes every 8 hr the p ores of the fil ter clo th are kep t open As .
,
.

thi s reverse c urrent bag shaki ng systemi s not qui te as efl ecti ve as shaki ng by
- -

hand or m echani cally there i s provi d ed an auxi li ary shaki ng devi ce consi sti ng
,

of hori zontal chai ns each enclosi ng the suspensi on wi res of a row of bags and
,

havi ng a strong spi ral sp ri ng i n the m i ddl e and handl es at the ends Pulli ng a .
 S MELTI NG LE AD ORE S I N TH E BLAS T F URN ACE

chai n and suddenly releasi ng i t causes the bag to recei ve a Vi bratory mo ti on from
,

top to bo t to m The d ust acc um

. ul ati ng i n the cell ars i s removed by a systemof

CROS S S ECT IO NAL ELEVAT lON S ECT IO NAI. ELEVAT ION

N o 8 S i ng le I
. N o. 8 Soft

FI GS to — Reverse current baghouse and sh aki ng devi ce, Tooele, U tah

4 10 4 5
1 -
. . .

screwand bel t conveyors di schargi ng i nto a car, i s th en p ugged , d d

and ad e to

the bl ast f urnace charges .

424 ME TALLURGY OF LE AD

The loss of Pb i n co nver ti ng i s fro m3 t cent that of Ag i s negli gi ble

o 5p er .
,
.

1 91 . composi ti on
—
Slag The .
— —
1 33) and di sposal ( 51 1 7 1 2 0) of lea d

slags have b een di sc ussed already .

W aste slag has b een used i n di flerent ways i nstead of allo wi ng i t to accumu
late ou the d ump Thus the heat of the slag has been uti li zed for heati ng .

blas t and for rai si ng steam; the slag has been cast i n the forms of bri cks
1 1
,

blocks ti les etc ; i t i s used for ball asti ng rai lroads macadami zi ng roads ;
,
1
,
.
,

granulated i t has gone i nto concrete etc

m
, .
,

E orescences on slags have been noti c ed by Iles Shel by w 1

hi ch they found -

to CO IISIS t O f K2804 and N assO 4 .

There remai ns to be consi dered th e cleani ng of slags that i s freei ng themof , ,

h r
t ei Ag co nt ne -
t if thi s i s t o o hi gh t o a llo w t h e m,
t o go t o w ta s e T h e A g
—c o n .

tent m ay be due to entangled p arti cles of lead b ulli on and especi ally of m atte .

Matte may be held i n sol uti on by the slag usually however i t , ,

i s held i n suspensi o n o w i ng to i m p erf e c t se t t li n g or t o s u p e rfi c i al o x i d at i o n

of matte ei ther by Fe304 contai ned i n the slag or by ai r whi le tap pi ng“ “ Thi s ,
.

oxi dati on sets free S02 whi ch adheri ng to pellets of matte hi nder themi n t he , ,

set tli ng Resm

. el ting m ay recover p ar ts of ent angled values but usually not

i n sufi ci ent am ounts to p ay for the cost ; addi ti on of Cu beari ng p yri te or

7 -

matte greatly assi sts i n desi lveri zi ng a slag Thus Keller smelted at “ .

Leadvi lle slag fro mtreati ng carbonate lead ore esti m ated to contai n oz Ag ,
.

p er t o n w i t h
,
1 3 p er c ent py ri t i c ore co ntai ni ng 1 0 p er c ent Cu and 1 1 oz Ag . . .

p er t on i n a n oblo n g b l a st f urn a c e 3 6 by 8 0 i n H e p u t t hr o u gh i n 2 4 hr 1 1 3 . .

to ns of charge wi th p er c en t cok e a li t t l e m ore t ha n h alf th e a m o u n t t h e n .

,

requi red to smel t ore charges There resul ted 5 3 p er cent matte contai ni ng -
. . .

2 0 p er c ent Cu and oz Ag p er ton showi ng a savi ng of 80 p er cent of t he

. .
,
.

si lver contai ned i n the o ri gi nal sl ag .

In ta ki ng a sam ple for analysi s froma freshl y drawn p ot Of slag the hard ,

ened surfac e i s perfor ated and a clean steel bar i nsert ed 3 i n i nto t he li qui d ,
.

slag and q ui ckly c hi ll ed by plungi ng i nto col d w ater So m eti m es slag i s di pped .

out fro mthe p ot wi th a cl ean cold i ron ladle p o ur ed out ag ai n af ter a m i nute or , ,

1
Bretherton, E ng . Mi n . J .
,
1 899 , v m6 ,
04 , 69 8 ; 1 900, m
ax , 61 4 , m , 760 ; M i n S c P res s
. .
,

1 900 . 13 000 . 5 72 ; ll 9 1 2 . 01V. 2 4 3

Lang E ng Mi n J 1 89 6, mm 78 ; Mi n S c Press, 1 89 8, D o wn 4 1 7 ; E ng Mi n J 1 90 9 ,
m9
. . . .
,
.
, , . .
,
.
,

Ix xxv ,
1 6 .

1
Gi roux, Mi n S e . . P ress, 1 89 3, v u, 34 .

H owell Ashcroft E ng M i n
-

,
. . J .
, 1 89 3, W I, 52 ; 1 894 , Lv m 56 ,
.

Lang op ci t 1 909 M
,
. .
, , , 96 .

GOp ner Vauti n, -

M etatl urgi e ,
1 9 1 0, VI I , 1 6 1 .

Johnso n M et ,
. Che m E ng . .
, 1 91 1 , x, 66 2 ; J . I ron and S teel I nst , . 1 9 1 4 , II , 98 .

Perki ns Barker, E ng M i n J , 1 9 1 2 , x c , 2 6 7
-
. . . m .

1 m
“
H of an, General M etall urgy, 1 9 1 8, p 4 69
"
. .

1
E ng Mi n J , 1 89 9 , v
. n, 650 . . .

1
H ari ng, Oesterr Z t B erg H fi ttenw, . . . . 1 893 , x u , 2 38 .

1
Vambera, Oesterr I ahrb , . . 1 90 3, LI , 1 35 .

1
Pi gott, E ng Mi n J , 1 9 1 6, on, 62 6 ; . . . see also p 371 . .

1 Tr A I M E , 1 89 2 9 3, xxr, 7 1
. . . . .
-
.
4 26 ME TALLURGY OF LE AD

The finer these parti cles the m ore rapi dly do accreti o ns form; thus wi th ,

galena concentrates accreti o ns form more rapi dly than wi th l um

, p galena .

Whi le they generally format the si d es rather than at the ends of a furnace i t ,

has been no ti ced i n som e i nst ances that wi th the i ncrease of the di stance bet ween

the t uye res t hey formm ore at the ends and are thi cker at the front than at th e
back .

The Cl aus thal analysi s where gal ena i s sm el t ed rawrepresents a crystalli zed
, ,

wall accreti on consi sti ng pri nci pally of galena At Tarnow

,
i tz wher e slag .
,

roas ted galena ri ch i n blende i s smel ted wi th the gray slag fro mthe reverbera
tory furnac es tw o ki nds of accreti ons for m one a sulp hi d e pri nci pally black
, , ,

the ot her an oxi di zed com po und ha vi ng a greeni sh color The three analyses by .

Guyard of Leadvi lle accreti ons (p rod uced when carbonate ores form ed if not ,

the whole at least the m

,
ajor part of the charge) show a great vari et y i n com

posi ti on The lead for i nstance i s present as metal as sulphi de, and as
.
, , ,

Oxi de ; zi nc arseni c and anti m

, ony as sulp hi des and as oxi des
, .

The m ethod of r em ovi ng these accreti ons whi le the furnace i s runni ng , ,

and t hei r treat m ent h ave b een di sc ussed i n § 1 72 .

1 93 H earth Accreti ons or S ow

. s — In a furnac e wi th an Arents si phon .

tap t hese unwelcom e prod uc ts formon top of the lea d belowthe tuy e res ; i n
'

f urnaces tapped fromthe bo tto m they formthere They result fro ma faul t y , .

charge or froma lack of fuel and are generally m i xtures of slag sp ei ss m at te

, , , ,

metalli c i ron metalli c lead coke and charcoal The metalli c i ron results
, , , .

fromthe red ucti on of ferri c oxi de some of i t bei ng held i n soluti on by mel ted ,

matte and dropped when thi s cools The i ron of a sowi s generally carburi zed .

and co ntai ns Si and P Analyses are gi ven i n Table 99 . .

I t does not usuall y p ay to work up a hearth accreti on ; i t i s thrown over

the d um p or b uri ed bei ng an eyesore Flechner suggests several met hods
,
1
.

of worki ng f urnace sows The followi ng used at the ni ckel works of Schwerte
-
.
,

i n W estphali a ( Prussi a) i s of i nterest Furnace sows contai ni ng from7 5 to

, .
-

8 5 p er cent Fe 5 to 8 p er c ent Cu 3 to 6 per cent Mo 2 to 4 p er c ent Ni Co

.
,
.
, .
, .
,

and wei ghi ng from500 to 600 lb api ec e are gr ad ually m elted down w i th coke .
,

on the bo t tomof a blast furnac e the m elted par ts r unni ng out co nti nuo usly , .

In thi s w ay a large crust i s easi ly r ed uc ed i n si ze and can then be ad ded agai n ,

to the ore charge where i t wi ll be taken up by the spei ss and the m

-

, atte Any .

mechani cal means of breaki ng up a hearth accreti on i s sure to cost more than
wi ll be recovered fro mresmel ti ng .

1 94 Furnace Cleani ngs and Furnace Refuse

.
— Furnace cleani ngs and refuse
are a m i xt ure of fire bri ck m etal beari ng m ateri al s f uel etc
-
ob tai ned i n
,
-

, , .
,

cleani ng out a blas t furnace when blown down They are assorted ; the waste .

goes to the slag heap the valuable par t i s added to the ore bed
-

,
-
.

1 9 5 Furnace Gases
.
— The co m p o si t i o n of b la s t f u
.rnac e gas has bee n g i v en

i n Table 75 As i t r uns hi gh i n N and as the am

. ount of C03 i t contai ns i s ,

greater than that of CO i t has no value as a gaseous fuel and goes to waste , , .

The recovery of d ust and f um e i t carri es alo ng wi th i t i s taken u i n

p 5 1 9 6 , .

1
Oesterr Zt B erg H fittenw 1 889 xxxvn 1 96
. . . .
, , , .
 S MELTI NG LEAD ORE S I N TH E BLAS T F UR N ACE 427

The gas carri es such s mall amo unt of SO. and SO; that i t can pass i nto the open
s

wi thout havi ng to be t reated to neutrali ze free aci ds .

TAB LE 99
— AN ALYSE S
. or H E AnTn ACCEE n ON s on So ws

( 0) E mmo ns l oc , . ci t 72 3 .
( b) B elli ng B erg H attenrn Z
. . . 1 86 7 . m . 419 .

1 96 . Flue or prod uct i s the materi al whi ch has

Cha ber Dust m -
.
1— Thi s
set tl ed from the gases i n t hei r p assage t hro ugh condensi ng flues c ham bers , ,

et c
. It i s m ade up of tw o com ponents whi ch merge i nto one another dust ,

proper and fume .

The d ust consi sts of parti cl es of the charge m ostly unal tered but som eti m es ,

chem i cally changed rangi ng i n si ze from16 and M i n to i m palpable powder ;

,
.

the f u me of metals and thei r compounds whi ch have been volati li zed i n the
,

lower part of the furnace and not cond ensed i n the upper The vap ors have .

been more or less oxi di zed ; so the fume may contai n sulphi des sulphates , ,

and o xi des of Pb Zn As Sb Se Te etc The fum e i s an i m

,
palp able powder
, , , , ,
.

whi ch collec ts mai nly on the walls of the condensi ng system; the major part
passes off wi th the gases unless i t i s arrested by fil trati on or elec t ri c preci pi ta
t i on . Som e d ust set tl es wi th fume and som e fum e wi th the d ust A ro ugh , .

1
H eri ng, C A
“Verdi chtung des H uttenrauches ,
. Cot ta, Stut tgart , 1 888 .

m “
Guille ai n, C , Theori e und Praxis der Staubverdi chtung und der Rei ni gung und Ent
.

staubung von Gasen,

”
Knapp , H allo, 1 9 1 1 ( ai nly a co p ilati on of Ger an p atents) m m m .

Ful ton, C A , Metallurgi cal Sm

“ oke, Bureau Mi nes B ull 84 , W ashi ngton,
. .
, .
5 1 91 .

H ofm
“General Metallur wH ill NewYork , 1 9 1 8
an H O , . .
, gy , M cGra -
Book Co .
, .

Ile
s ,
M i n J 1 886 X LI 74 9 3 1 4 8 ; S chool Mi n Quart ,
E ng . . .
, , , , , . 1 89 5 9 6, XVII , 9 7
-
.

Fri edri ch, Metallurgie 1 906, III 74 7 , , .

Ingalls, Eng M i n J , 1 9 1 1 , x cn 1 1 1 5
. . .
, .

Schi fi ner, M etall n E ra 1 9 1 4 , X I 2 57 2 78 . .

, ,
-
.
428 ME TALLURGY OF LE AD

di sti ncti on made by the amount of i n oluble r i d ue each contai ns ;

ca n be s es

du t contai ns over fume under 5 p er cent In ol

s , . s .

Table 00 gi ves so m e older analy es of flue d u t fromvari o us sm

1 elteri es s -
s ,

TAB LE 1 00 .
— AN ALY SE S or FLUE —
DU S T rnon VAnrous S H E LTE RIES

T race

1 00

2 25

I 1 7

( 2 ) Curt i s Tr A I M E 1 8 73 7 4 11 9 5 ( b) Dewey B ullet i n No 4 2 Uni ted S tates Nat i onal

m
. . . . .
. . . . . .

Museu .
"
1 89 1 p 53 ( e) Belli ng M etatthauenlrnnde 1 885 p 8 7
. . .( a) Freudenberg M D i e auf der . . . . . . . ,
"

Blei h utte bei E m s zur Ge w Em

”
i nnung den Pl ugsta ubes get roffenen Ei nri ch tungen s 1 8 8 2 p 1 9 ; Abs t r

m
. . . .

mm
.

“
E ng . Mi n . J E gl est on Tr A I M E
1 882 . 1 88 2 83 111 3 79 ; Stet efeldt ,
. 14; Co ent on . . . . .
-
. .

Freudenberg s Pl ates . E ng M i n J . 1 883 . xxxvI. 5 1 ( 1) French E ng M i n

'
( e) H eri ng op ci t p 3 4
"

m
. . . . , . .

m
. . . . . .

J . 1 8 80. n ut . 4 9
.
( l ) Kos ann. Z t Berg B atten S al W i Pr , 1 883
. 1. 2 2 7 01) As oxi des (i) . . . . . . . . . .

I nsol uble resi due .

and Table om e m ore recent data fromthe works of the Globe Smel ti ng
1 01 s

and Refini ng Co Denver Colo com muni cated by M W 1105 .

, , .
,
. . .

The analyses do not take any cogni zance of the presence of NH . Thi s .

has been no ti ced by several m etall urgi sts Iles ob served i t i n i ci cl es at tached
1
.

to the cond ui t pi pes l eadi ng to the bag ho use Canby Dwi gh t and Sem
1 1
ple1
.
, ,

1
E ng . Mi n . J .
, 1 889 , v m5 76
, .

1
Loc . ci t
p 633.
,
. .

1
Tr. A I M E ,
. . . .
74 6
1 9 1 2 , x u n, .

1
Eng . Mi n . J .
, 1 9 1 3, xcv, 1 2 08 .
430 ME TALLURGY OF LE AD

carri ed out of the furnace i f the qui ck ascent of the gases be not checked by the ,

formof the furnace (by havi ng boshes) E xtreme figures of the amo unt of flue .

d ust formed are and 1 5 p er c ent of the w ei gh t of the ore ch arg ed

1
An . .

averag e figur e used to be 5 p er cent ; th i s has fallen to 2 p er cent sinc e blast . .

roasted m ateri al has form ed 70 to 80 p er c ent of the charge . .

The charac ter and conseq uent value of flu e d ust changes grea tly accordi ng -

to the par t of the flue i n whi ch i t i s collec ted N ear the blast furnace i t wi ll .

r esemble very much the ore that was charged fur ther on i t will grow ri ch er in ,

Pb and lower i n Ag unti l all ore par ti cles hav e been settl ed out and only fum e ,

r emai ns susp ended i n the gas current Thi s will be very ri ch i n Pb and very .

p oor i n Ag T h u s fi l t ered. f um e co m i ng fro m bl a st fu rn a c es pro d u c i ng l ea d

b ulli on assayi ng from300 to 500 oz Ag p er ton will assay only abo ut 4 oz Th is . .

was shown very clearly i n the F L Bartlett process It m ay be fur th er . .

i llustrated by tw o i nsta nc es one of am ple and one of i nsuffi ci ent condensati o n , .

The dust co llec ted at a d i stanc e of 6 2 5 ft fromthe blast furnace conta ined fro m .

2 0 to 2 5 p er c ent Pb and 50 oz Ag p er ton ; af ter p assi ng the rest of the w

. ay a .
,

flue 501 0 ft long i t contai ned 65 p er cent Pb and 1 oz Ag p er ton

.
, In the . . .

seco nd i nstanc e the d ust b eh i nd the blast fur nace assayed 35 p er cent Pb and
, .

3 1 o z . A gp er t on ; i n t h e m ai n d ust ch a m b er 4 1 p er c en t P b a nd 2 6 oz A gp er , . .

ton ; at the foo t of the stack 52 p er c ent Pb and 1 7 oz Ag p er ton , . . .

The flue d ust from roasti ng and reverberatory sm

-
el ti ng furnac es blast ,

roasti ng apparatus and conver ters i s li gh t colored as the processes are oxi , ,

di zi ng; the d ust and fum e are th er efore com posed of oxi d ized materials and ,

contai n prac ti cally no carbonaceous matter The amount formed vari es too .

much to permi t maki ng a general statement ; numeri cal data have been gi ven
wi th the several furnaces .

1 97 Recovery of Flue dust and M

. e ; General
1—
The m ethod s -
in .

operati on at lead sm el ter i es and r efi neri es m aybe classed as dry w et and elec t ri c , , .

D ry m ethods of co ll ec ti on are used al m ost exclusi vely i n the Uni ted S tates and
do excellent work Wet methods were i n Op erati on at the Chel tenh amW ork s
.

of the St Lo ui s Smelti ng W orks ; th ey have fo und much favor i n E urop ea n

.
1

works E lectri c condensati o n of fume by means of the Co ttrell process i s

.

maki ng much h eadway in lead plants and promi ses in ti me to replace the bag
ho use whi ch at present serves thi s purpo se .

Whatever method may be used for collec ting dust and fum e the gases ,

i ssui ng fromthe furnaces travel through flues and perhap s cham bers in whi ch
th ey drop m o st of thei r dust and then pass on to speci al condensati on ap p aratus
1 98 DryCollecti on of Dust and Fum
, .

. e — The steps necessary for sati sfac to ry .

work are cooli ng of gas and retardati on of i ts veloci ty wi th settli ng of dust

, ,

to be followed wh en necessary by fil trati on for the collec ti on of fum

, e , .

1 99 Cooli ng of Gas
.
— Cooli ng of gas i s essenti al to reduce the tem perature
1
H ahn, M i n Res U S 1 882 p 344 . . . .
, ,
. .

1
Iles S chool M i n Quark 1 896 XVI I 9 77
, .
, , ,
.

H o fman
“ General Metallurgy, 1 9 1 8 83 1
”
.
, ,

1
Iles, loc . ci t .
, p . 1 05 .
 S M ELTI NG LE AD ORE S I N TH E BLAS T F URN ACE

to a poi nt at whi ch volati li z ed metal or metac co m po und ceases to exi st i n the

state of vapor The si ngle par ti cles susp ended i n the gas current are brough t
.

togeth er m ore closely and uni te i nto flaky masses whi ch set tle more or less ,

readi ly Cold surfaces attrac t par ti cles; hot surfaces speci ally wh en mo i st rep el
.
, ,

them 1
.

Tho ugh the gases froma l ead blast furnac e run wi th a cool top req ui re v ery
li ttle coo li ng the fine dust and vapor com
,
i ng fromreverberato ry sm el ti ng and

refini ng furnaces are li k ely to be lost i f th ei r temp eratures are not reduced ,
.

PbS sub li m
°
In a current of ai r Pb i s volati l e at above 500 C Pho at es .

i n a curr ent of N at Zuo r eq ui r es a h i gh er tem perature than Pho The .

saturati on c urve for Asa

1
of E l ton i s gi ven i n Fi g 4 1 6 I t sho ws e g that
1
, ,
. .
, . .
,

C ) 1 cu ft under
°
at 833 F . . . .

standard co ndi ti o ns w i ll hold lb

a”
. .

° °
As.o. and at 2 50 F C ) o nly a g
° ‘

,
1 21 . .

The gas current m

a
trace ust th er efore
t
. e
-
r

be cooled to 1 2 1 C i f all the A5 20. i s to m

e
° p
.

e
be cond ensed The gas SO: ca o t e n
. n b T

condensed by ordi nary cooli ng methods ”0

01
.

o
The vapor S03 s prese t n g
i i n
°
n a s es u n A s o p O n d o Lb , ,
or . a .

comb ined W i th H 1O at 44 0 C ; between FIG 4 1 6 —Vapor tensi on curve of °

°
. .
-

°
35 0 a n d 44 0 a bo ut h alf t h e v a por i s

i n com b i nati on wi th H gO ; at about 338 the 803 has been wholly changed i nto °

H zSO 4 but i s sti ll i n the state of vapor ; betw

°
,
een 2 00 and 338 the vapor i s
i n p ar t conver ted into a m i st ; at 2 00 i t b egi ns to be com
°
p l e te ly co n d en s e d i a ,
. .
,

H aSO4 of 6 2 Bé ( sp gr 5)
°
b eg i n s to b e v apor.i z ed at t h i s t em p er
. a t u re I.n .

g eneral i t may be sai d that i f gases l eave the sta ck at a temp erature twi ce as ,

hi gh as that of the surro undi ng atmosphere the coo li ng has b een ca rri ed as ,

far as i t i s possi ble wi thout resor ti ng to i nd uced draft .

The com mon medi um for cooling fines and chambers i s atmospheri c ai r;
i n som e i nstanc es th i s has b een suppl em ented by th e use of w ater .

At present flues are bui lt o f sheet i ro n and bri ck w ork Formerly rei n .

forc ed co ncrete a coarse latti ce of i ron wi re or exp anded metal imbedded i n

, ,

c ement concrete was much i n favor on account of the effi c i ent coo li ng by
1 1
,

th e th i n walls but has fallen i nto di suse as the walls crack ed and were at tack ed
, ,

by sulph uro us gases In an i ro n p ip e there i s a loss of .B t u p er sq . . . .

1
Ai tk en, Proc Roy S oc , E di nburgh , 1 9 1 3 , xxxn , 1 83
. . . .

Russell, P hil Trans Roy S oc , 1 903 , ccr, A, p p 1 8 5, 55 1

. . . . . .

“
W elsh, H V D uschak , L H , Vapor Pressure of Arseni ous Oxi de,
1
. .
-
. . Bur . Mi nes ,

T echn Pap er 8 1 , W ashi ngt on, 1 9 1 5

. .

1
Tr A I . . . M . E .
,
1 91 3 , X LVI 69 7 , .

1
Moni er flue : B auer, Frei berg J ahrb , . . 1 894 , 39 ; E ng . Mi n. J .
, 1 89 5, LIX, 34 2 ; Mi n .

I nd v I89 51 IV, 4 78
1
Messi ter, E ng N ews, 1 899 , x , 3 5 ; M i n I nd
6 . m . .
,
1 900 , D 1, 4 55 .

E dw ards, Tr A I M E , 1 905, xxx v, 60, 9 6 5

mm
. . . . . .

W elsh ,
E ng . Mi n . J .
, 1 904 , , 3 4 8 .

H ai n, E ng N ews, . 1 90 5, a n, 2 79 ; Mi n . I nd .
,
1 90 5, e 417 .
432 ME TALLURGY OF LE AD

ft p er
. mi n
for 1 F di fi erence to
. Cal p er sq ft p er m
°
i n for 1 C) . . . . .
°
.

between the o utsi de of the pi pe and the surro unding ai r; Anderson gi ves the
1 1

rate of transmi ssi on thro ugh sh eet steel plates abo ut 16 i n thi ck as to ,
-
.
,

B t u per sq ft p er m Cal p er sq ft perm

°
. . i n p er 1 F
. to . in . . . . . . .

p er 1 Th
°
e val ue s ho w ev er v ary w i th th e cl eanli ness of fl ue co nvectio n , , ,

of wi nd exposure to sun etc and increase wi th the temp erature o f the pipe
, ,
.
,
.

I n a br i ck flue wi th si d es 1 3 i n and roof 9 i n th i ck th ere i s i n a 1 00 ft fl ue a loss . .

-
.

of C for every degree di fl erence b etween gas i nsi de and ai r o utside

.
1

m 009 9 6 !CO NVERTER FLU!

am
BLAS T ango; FLU!

; m u m 14
h as orno.
-e .
0300Tu :
ru ors xl
'
m .

cn
a h
1
Da h I h
“a rm
e: n n . In
In . m
m
w
.
.

ll l o :

FI G — Susp ended sheet i ro n FI G S 1 8 an d 419 —

Susp ended sheet i ron 00n
41 7 4
- -
. . . .

blast f urnace flue, O mh a a, N eb . verter flue, O aha, N eb m .

Fi g 4 1 7 i s shown the susp ended sheet i ro n blast furnac e flue of O aha.

In .
1 -
m
N eb , whi ch i s 1 400 ft long The gases fro the blast furnaces enter a bri ck
. . . m
fine b efore th ey pass i nto the sh eet i ron flue whi ch i s connec ted w i th a fan de -

li veri ng the coo led gas to the bag h ouse .

Fi gs 4 1 8 and 4 1 9 r ep resent the sh eet i ron conver ter fine of Om

1
. aha N eb -

,
.
,

whi ch i s 1 2 50 ft long The gases are drawn through the flue by a fan at the . .

cu ft p er m Th ey enter the flue wi th a tem

°
rate of in p era t ur.e of 37 1 . .

°
and leave i t at 1 2 1 C .

The supp or ted balloo n shap ed flue of Too ele U tah i s show n i n Figs 4 20 -

, ,
.

4 42 I.t i s mad e of pl a t e i ro n i n t h i ck a nd c arr i es th e g as es fro m th e .

,

bla st furnac es to the bag h ouse A vo lum e of cu ft p er m i n enters . . . .

°
tr av el s at the rate of 1 8 ft p er sec and l eav es at 84 C
°
th e flue at 1 0 2 C .
,
. .
,
.

1
N orton, C L , p ri vate co uni cat i on, January, 1 9 1 8
. . mm .

1
Tr A I M E , 1 9 1 6, x u x , 5 75
m 49 7
. . . . . .

1
Lee, B ull Tech E ng S oc Colo S chool M l n , 1 909 , IV, 1 9 7 ;
. . . . . . Mi n . I nd .
, 1 909 , xv ,
.

1
E ilers, Tr A I M E , 1 9 1 2 , X LIV, 708 . . . . . .

1
Eilers, loc . ci t .
434 ME TALLUROY OF L E AD

cooli ng At Frei berg Saxony oblong flues of sheet lead used to be cooled w
. i th , ,
1

water adm i tted onto the roof w hi ch tri ckled down over the si des At Tarnow i tz .
,

Si l esi a b undl es of pi pes w

1
, i th ci rculati ng water used to be suspended thro ugh
the arch of a bri ck fl ue ; adh eri ng f um e was hosed 05 at i ntervals At o ther .

places cooled sol uti ons were ci rc ulated i n coi ls of i ron pi pe placed at cer tai n
i ntervals i n the flue 1
.

f
Rei n orced Concret e
"
8 111 2 . 12 x 12

FIG 4 2 5 . .
-
Bri ck dust flue, -
strai ght si de -
walls . FI G 4 2 6
.
— Bri ck dust flue,
.
-
catenary wall .

2 00 . Retardati on of Gas Current and Settli ng of Dust — The gases i n t he

downco m er of the bl ast f ur nace h ave a veloc i ty of 2 0 t o 30 ft p er sec Recent . .

1 1 “
i nvesti gati ons by Shelby Moore and W ri gh t Lee Good ale and Klep i nger i n "
, , ,

connecti on wi th copper blast f urnaces have shown that d ust i s settled sati sfac
tori l y i f i n a clear open flue or cham
,
ber the veloci ty i s reduced to 2 16 ft p er sec . .

and the gases rem ai n 50 sec i n i t or to 5 ft p er sec i n a fine or cham ber hung .
,
. .

wi th wi res Wi th lead plants whi ch collec t unsettled fume by filtrati on or

.

el ec t ri c preci pi tati on t he veloci ty need no t be r ed uced to below 4 or 5 ft p er .

sec provi d ed the gases rem

. ai n 70 sec i n t he fl ue or cham ber The chi mney . .

veloci ty sho uld not be greater than 2 0 or 2 5 ft p er sec . .

Retardati on of gases i s usually acco m pli shed by change of di recti on of flue;

by suspensi on i n flue of plates at ri gh t angles to gas current ; by enlargement -

of flue to chamber ; by al ternate enlargement and contracti on of flue; by susp en

si on of pl ates i n flue parall el w i th gas c urrent ; by suspensi on of wi r es i n flue
m
.

The relati ve e ci ency of these d ust arresti ng devi ces has b een determ i ned -

exp eri m entally by Good ale and Klep i nger; th ei r resul ts are gi ven below i n 52 06
1 .

1
H agen, Frei berg J ahrb , . . 1 8 79 , p . 1 71 .

1
Saeger, Z t B erg H rltten S al W i Pr , 1 89 3, x LV, 2 80
’

. . . . . . . .

1
Sct sser -
E rnst, B erg H rttten .
‘

mZ
. .
,
1 885, X LIV , 4 64 ; 1 88 7, X LVI ,
1 34 .
1
E ng . Mi n . J .
, 1 908, Lxxxv, 2 05.
1
Op . ci t .
,
1 9 1 0, Lxx mx , 44 9 ; x c, 1 04 , 1 1 1 , 1 1 2.
“
Op . ci t .
,
1 1
9 ,0 x c, 504 .

1
Tr A I . . . M . E .
, 1 9 1 3, X LVI , 6
5 7 .

1
Tr A I . . . M . E .
,
1 9 3
1 , X LVI , 580 .
 S MELTI NG LE AD ORE S I N TH E BLAS T F URNACE 435

2 01 Change of Di recti on of Flue

.
— In the older E uropean lead works
it w as c usto m
ary to b ui l d long bri ck fl ues ; these cool ed th e gases and retarded

the veloci ty on acco unt of the fri cti on between stati onary walls and t raveli ng
g a s .T h u s a t Fr e i berg , Sa x o ny t h er e are i n Op er,ati on fl u es 5 m i l es lo ng , .

In ord er to decrease th e length zi g zag flues as shown di agram mati cally in

,
-

Fi g 4 2 7 have been b ui l t
.
, It w as fo und .

t hat so m e d ust acc um ulated at every

change of di recti on of gas c urrent ; they
were ther efore an i mprovement on the
strai gh t lo ng flue as regards coll ec ti on of

d ust and at the sam

, e ti m e caused a

savi ng i n b ui ldi ng m ateri al ; but the ad

di ti onal am o unt of dust collec ted i s small .

As lo ng as such zi g zag fi nes are b ui lt on Fm 4 2 7 —Zi g zag flue p lan

-

-
. . .
,

pi llars or are suspended so that ai r can

play aro und them they are efl ecti ve Thus the custo mary balloon flue
, .
,
-

( Fi gs 4 1 7 . usually b ui l t i n a st rai gh t li ne can be erec ted to cover a ,

sm all er floor sp ac e -
.

2 02 Suspensi on in Flue of Plates at Ri ght Angle to Gas Current

.
— Plat es
can be i nt roduc ed i nto a fl ue i n a m anner to forc e the gas c urrent to travel

i n a si nuo us p at h ei ther i n a hori zo ntal or a ver ti cal plane Bo th arrangem ents .

have an efl ect si m i l ar to that of a zi g zag flue exc epti ng that the tem perature -

'

i s not reduced as effec ti vely Gases traveli ng along a serpenti ne path i n a

.

hori zontal plane wi ll not drop dust as readi ly as when thei r co urse i s d eflec ted
sli gh tly up and down as h er e t he d ust dropped on the do w, nw ard t ravel can

be coll ec ted i n a pock et i n w hi ch there i s no movement of ai r Many E uropean .

plants have adop ted thi s construc ti on See curves 35 and 36 i n Fi g 43 7

ent of Flue to Cham
. . .

2 03 Enlargem —
ber Increase of si ze of a flue to a .

chamber effec ti vely decreases the veloci ty of the gas c urrent and thereby -

favors settli ng of dust Upon enteri ng the chamber the veloci ty i s slackened
.
,

grad ually to the poi nt where the draft near the exi t begi ns to Show i ts cflect ;
th en ther ei s a grad ual i ncrease i n veloci ty The cham ber ho wever sho uld not .
, ,

be too larg e as the gas c urrent do es not expand to fill the enti re cham
1
,
ber ;
i t travels o nly thro ugh p art of i t and then onl y par t of the enl arged flue or ,

chamber i s really uti li zed i n the set tli ng of dust It has been suggested that .

th e app ro ach to the cham ber sho ul d be tapered as the di spersi on of the gas ,

c urrent i n the chamber wo uld be i ncreased and thus a larger part utili zed
for settli ng 1
See c urves 3 2 and 34 i n Fi g 4 37
2 04 Al ternate Enlargem
. . .

. ent and Contracti on of Flue — If as shown i n ,

a si ngl e great enl argem ent of flue i s not lik ely to utili ze t o the f ull extent

t he cross sec ti onal area of a cham

-
ber repeti ti on of the process w i th sm all ,

enl argem ents o ugh t to be m ore sati sfactory So far thi s m ethod has not .

fo und m uch appli cati on See c urve 37 i n Fi g 4 3 7 . . .

1
Messi ter M i n S c Press 1 908 XCVII 2 6
, . .
, , ,
.

1
Wedge dust cha mber , E ng . Mi n . J .
,
191 6, CI , 64 6 .
436 ME TALL URCY OF LEAD

2 05 . Suspensi on of Plates in Flue Parallel wi th Gas Current — In the ap

parat us referred to there has been p assed over the consi derati on of the fri cti on
between stati onary walls of flue and movi ng gas c urrent whi ch i s the cause ,

of the reducti on of veloci ty It i s Freudenberg s meri t to have di scovered

1
.
’
,

that an i ncrease of surfac e i s an efl ecti ve m eans of settli ng d ust and that t he ,

am o unt of settled dust i s i n di rect proporti on to the area of surface wi th whi ch

FI GS 4 2 8 to 4 33 — Flue w
. i th Freudenberg p lates, Frei berg, Saxony
. .

the gas comes i n contac t The cooler the surfac e the great er wi ll be i ts attrae
.
,

ti on for suspended par ti cles 1

In ord er to i ncrease the surface area Freudenberg
.
,

suspend ed at the l ead w orks of E ms Prussi a t hi n sheet i ron plates parallel

1
,
-

wi th the gas c urrent and to prevent settled dust fromb ei ng carri ed off he
,

, ,

1 “
Freudenberg, M , Di e auf der Bleih il t te bei E s zur Gew
. m
i nnung des Flugstaubes getro fl
Em s, 1 882 ; Abstr , E ng M i n J , 1 882 , xxe
”
eaen E i nri ch t ungen, , 1
. . . . .

Egleston, Tr A I M E , 1 88 2 83, x 1 , 3 79
. . . . .
-
.

Stetefeldt , Co m
“ m
ent on Freudenberg s Plates,
’
E ng Mi n J , 1 883, xxxvr, 51 . . . .

1
Ai t ken—Russell p 4 3 1 ,
. .

1
Ill u trated i n f
re erence .
438 ME TALLURGY OF LE AD

In 1 900
1
the Mi ning Co com p leted at i ts plant of Great
Anaco nda Copp er .

Falls M ont the new flue sy stem of w

,
.
,
hi ch the Ro esi ng wi re systemforms - -

an i ntegr al par t The pap er has to be co nsul ted fully to study thi s
.

adm i rabl e system of collec ti ng flue dust The par t that i s of m ain i ntere
s t -
.

here i s th e dust cham b er 367 by 1 77 ft and 2 1 ft hi gh fromthe top s of the . .

hOpp ers whi ch formthe floor to the roof

,
Th e cham ber is hung for a dis ,
.

tance of 3 1 7 ft wi th steel wi r es spaced

. in The gases travel at .

ri gh t angles to the suspend ed wi res Th e wi res wei ghing each abo ut 1 lh .

,
.
,

are h ung i n tw o gro up s wi th a clear space 4 7 ft long i nterveni ng for the p ur ,

.
, ,

pose of collec ting dust i n the entrance and fum e i n the exi t di vi si on At the ,
.

i nlet end th ere i s lef t a clear space for the even di stri b uti on of th e gases ; i n

FI GS .
4 34 to 4 36
— Roesi ng
. wi re system Tarnowi tz
-

, ,
Silesia .

the first 51 ft of the cha b er the wi res are

. in i n m
di ameter and 1 6 ft long ; . .

the rest of the wi red space has wi r es i n i n di a meter and 2 0 ft long At . . .

the upp er end of the entrance di vi si on th ere are 2 2 p i p es for th e adm i ssi o n of ai r
to cool th e gases to the d esi r ed tem perature The wi res are susp end ed froma .

netti ng of steel w i re wi th 1 % i n op eni ngs bol ted to the I beam

,
s of th e roof -
.
,
-
.

The suspended wi res are sh ak en for 30 m i n at intervals of 60 to 90 days by .

means of angle frames suspended by hangers thro ugh connecti ng rods extend
-

, ,

i ng thro ugh the flue w alls and at tach ed to a b ell crank lev er
-
The effi ci ency of -
.

the wi re systemi s shown i n c urves 38 and 39 of Fi g 43 7

-
. .

2 07 E fi ci ency of Dust arresti ng Devi ces

.
— The tests of Goodale and -

K lep i nger were carr i ed on i n an experi m ental flue 4 ft w i de by 4 ft 6 i n hi gh ,

. . .

and 304 ft lo ng havi ng a furnace gas i nlet at one end and an exh aust fan at the
.
,
- -

o ther The velo ci ty of the gases ranged from

. to ft p er sec and the . .
,

tem perature was 4 00 F ( 2 04 C ) The resul ts ob tained i n the first 300

° °
. .

ft of the cham
. b er are shown i n Fi g 437 The ordi nate at the left gi ves . .

the pound s of dust and fum

°
e coll ec ted p er cu ft gas at 400 F . . .

Goodale -
Klep i nger Tr A I , . . . M . E .
,
1 9 1 3, x wr , 56 7 .
 S MEL TI NG LE AD ORE S I N TH E BLAS T F URN ACE 4 39

°
( 2 04 r i gh t e p
the one at the
th e rc enta g e of th e to ta l d u st recov er ed ,

the to tal of 1 00 p er cent bei ng arri ved at by fil teri ng a m easur ed vol um

. e of

g as thro ugh mi nera l wool Th e ab sc i ssa g i v es th e l eng th of th e

. fl ue un d er
consi derati on .

Tests 3 2 and 34 show that in the Op en flue wi tho ut any obst ruc ti on what ,
~

ever and w i th veloci ti es of gas of and ft p er sec there were co llected . .

,

i n 300 ft of cham b er between 30 and 40 p er cent of the d ust

. . .

Test 33 i ndi cates that ov er 40 p er c ent of the dust w as recov ered wh en .

,

1 1 rows of lo ngi tud i nal surface plates ( 2 5 by 35 in and in thi ck ) i a . .

, . .

m
100 5 0
w
150 zo
o
W th d o
‘
h l ut

F m .
437
— Re
.la ti ve efli ci ency of dust -
arresti ng devi ces, Great Falls, Mont .

Freudenberg plates were hung 4 i n apart i n the flue for a di stance of 1 70 ft

, .

cro ss plates -

, 8 i n h i gh were placed 1 0 ft apar t on the floor

.
, The v elo ci ty of . .

was
ft p er sec
m
the gas . .

Tests 35 and 36 exhi b i t the eflects of 3% i n pla te ha es pla c ed .

staggeri ngly acro ss the flue so th at they present th ei r surfaces to th e gas curren t ; -

plates ,
hi gh were pla ced every 1 0 ft on the floor to arres t settled dust In
8 in .
,
. .

t est 35 th e baffl es i w i d w r p d d i p r w i h op p c
m
, 5 n e e e su s e n
,
e 7 n a a
. t t , en s a es .
,

5% i n b et w
. ee n b affl es an d 2 % i n b e tw ee n b a e s a nd w all s i n t wo d i.vi si o ns , ,

9 2 ft lo
. ng se p a ra t ed by, a cl ea r sp a c e of 1 00 ft I n te s t 3 6 b afll e s 3% i n w i d e .
, , .
,

were used thro ugho ut the fi ne wi th the excep ti on of abo ut 8 ft a t the end The . .

-
i h bafll es eflected a savi ng of over 80 p er cent of th e d ust wi th a gas
. .

veloci ty of ft p er sec ; the i n baffl es one of 70 p er cent wi th a veloci ty

. .
-
. .

of ft p er sec . .
4 40 ME TALL URGY OF L EA D

Test 37 disp lays the effects of expansi ons and contrac ti ons of the flue . Th e
flue, 1 8 sq ft in cro ss sec ti o nal area, w
. as par tly closed a t 1 00 and 1 04 ft
.
-
from .

the ends by tw o p ar ti ti ons each havi ng a c entral p i pe 1 8 5 i n in di am eter or a,

. .

cross sec ti onal area of

-
sq ft This si m ple contri vance caused a savi ng of . .

over 70 p er cent Of the d ust wi th a gas veloci ty of . ft p er sec -

. .

Tests 38 and 39 bri ng out clearly the great saving of dust accom p li shed by
-
m
wi re ha es or the Roesing system Copper wi res N o 7 B S gauge were .
, . . .
,

susp end ed fro mpo ul t ry net ting at 2 and 2 5 i n centers to ex tend fro mroof to .
-
.

floor In test 38 t wo 50 ft sec ti ons were hung wi th wi res ; i t presents a savi ng

.
,
-
.

of close on to 80 p er cent of the dust wi th a gas veloci ty of ft p er sec and

.
-
. .
,

d emonstrates i n a stri k i ng m anner the di fl erence b etween a wi red and a clea r

flue . In test 39 the fi ne w as h ung thro ugho ut wi th wi r es wi th the exc ep ti on

,

of 9 ft at the end ; i t shows the greatest savi ng about 85 per cent wi th a gas
.
, .
,

veloci ty of ft p er sec . .

As a resul t of th ese tests the newdust cham b er of Great Falls has b een p ro ,

vi ded wi th wi re bafi es as o utli ned -

.

2 08 Filtrati on of Fum
. c, General 1 — The fum es of lead furnace s whi ch have .

no t b een coll ec ted wi th the d ust are recov ered at p r esent m ai nly by passi ng

themthrough susp end ed co tton or woolen bag s These allow the gases to pass .

freely through the mesh es but retai n the fume and the fine d ust whi ch has ,

rem ai ned i n suspensi on owi ng to i m perfec t settli ng .

Clo ths stretch ed up and down i n zi g zag across a dust cham ber ( Brown - -

D eCam p f um e co ll ec tor ) w er e o nc e used as a fi l ter at O m ah a N eh ’

T h e , .

fil teri ng w as sati sfac tory but th e di fi culty and exp ense of m ak i ng repai rs in
,

the clo th were too great to warrant conti nui ng work wi th th is d evi ce .

A bag ho use w i ll be used for fil teri ng if the values recovered are suffi ci ently
8

large to p ay for the i nstallati on and the cost of Operati ng bo th of whi ch are ,

hi gh or if i t i s necessary to prevent metalli c compo unds frompassing ofl into

‘
,

the atm osphere whi ch would do damage to the co untry i n the nei ghborhood ,
it m ay serv e also to prevent lo sses duri ng ab norm al worki ngs of the furnace s .

Unfortunately fil teri ng recovers all the fum es h enc e also Aszoa a by p rod uc t , ,
-

whi ch i t i s Often di fi cult to market .

I t has b een shown that i n lead blast furnaces run wi th cold tops the loss in
metal i s caused mainly by parti cles of dust as the furnaces mak e very li ttle ,

fume As long as th ere has b een made adeq uate provi si on for settli ng d ust
.
,

a bag ho use will not be need ed .

E i lers d iscussi ng the bag house of the sm

“ ,
el tery at Murray Utah whi ch , ,

sm el ts si lver lead ores wi th charges contai ning 1 0 to 1 2 p er c ent Pb and tha t of

-
.
,

the sm el tery at Om ah a Neb whi ch tr eats in the blast furnac e charges runni ng ,
.
,

Iles, lac ci t

m m vm
. .

E baugh, I nd E ng Che , 1 909 , 1 , 686 ; E ng Mi n J , 1 909 , L

J . . . . . . .
, 1 02 0 .

E ng Mi n J , 1 89 5, 1x , 3 72
. . . .

Iles , M W ,
“Lead S elti n ” W ile N ewYork 1 0 2
g,
.
y , , 9 , p
.
p 1 86 m .
-
21 1 .

A bag house w i th 4 000 bags costs about

Edi tor, E ng Mi n J , 1 909 , . . . m m ,

1 02 1 .

Tr A I M E , 1 9 1 2 , xxxv, 708
. . . . . .
44 2 ME TALLURGY OF L E AD

B uc hler Ban -
mann of Rigg ,
l
s,
’
can only be no ted, as i s th e case wi th m
the ca els
hai r fil te r of Camron e .
8

2 09 . Bag Filtrati on at Murray, Uteh .

‘— Th i s bag ho use, shown i n Figs 438 .

4 53, was erec ted in 1 906 at a cost of and went in to op erati on in

0 The e e ati l v ons and sec ti o ns Fi gs 8— gi ve th e leadi ng features

1 9 7 .
,
.
43 44 2 ,
.

The bag ho use, 216 ft 6 i n . . by 90 ft 6 in . . and 5 1 ft 6 i n

. . hi gh to roof trusses ,

“A“ M
m
END ELEVATD
ON W ING 0 I TEEI. COUTH ELEVATlON CH OW Ul O CO UTH ELEVATlON GRO W IN G Of
w
T o or w
e rous out n or -
TN ! CIR FOOT " i n ar
-

OTEELOTM

6 fl ue

Fl ue to Fen Fl ue

EAST EN D ELEVAT IO N S ECT ION

FIGS .
4 38 to 44 2 .
— Ba
g filtrati on, M urray, Utah .

is b ui l t of bri ck ; the o utsi de walls are 2 1 in thi ck for a hei gh t of 1 6 ft are . .

,

reduced to 1 7 in for 1 8 ft and to 1 3 in for the remai ni ng 1 7 ft 6 in B ut tresses

. .
,
. . . ,

1 5 to a si de and
5 t o an en d are b ui l t i nto the wall s to st r eng th en th em; they ,

are 2 4 i n thi ck proj ec t 4 ft at the floor li ne and taper to 1 ft at the line of the
.
, .
-
.

I ngalls, E ng M i n J , 1 9 1 8, CV, 9 7
. . . .

U S Patent, No 1 09 50 76, May 5, 1 9 1 4

. . .

m
.

M et Che E ng , 1 9 1 7,
. m .
, 2 84 ; E ng M i n J
. m . . .
,
1 91 7, c , 1 0 72 .

Eilers, Tr A I . . . M . E .
, 1 1
9 ,2 x u v, 708 .
 S MELTI NG LE AD ORE S I N TH E BLAS T F URN ACE

roof trees The detai ls of constr ucti on of the roof are shown i n Fi g 44 3
-
. . .

Th e bag ho use has fo ur steel stacks Fi gs 4 38 44 2 6 ft in di am — eter and 78 ft ,

.
, . .

hi gh one for each com

,
par tment to draw ofl the gases The m oi sture that .

co ndenses i nsi de and tri ckles down is collec ted Fi gs 444 and 44 5 in a lead li ned ,
.
,
-

p an ; th i s i s h u n g at a s u ffi c i en t d i sta nc e b e ne a t h th e i n l e t so as not to

i nterfere wi th th e draf t ; fro mi t a lead gut ter runs out on to the roof .

The bag ho use i s di vi d ed i nto fo ur b ay s by three bri ck p ar ti ti on walls ,

b Fi g 44 6 of the sam
,
. e co nstr uc ti o n as the o utsi d e wall s whi ch ex tend fro m
, ,

the floor li ne to the ap ex of the roof

-
Below the th i m ble floor 0 Fi gs 44 1 .
-

, , .
,

44 2 a
, n d 44 6 ea ch ba y i s d i vi d ed i nt o
,
fo ur ch am b e r s or c e ll a r s by 1 3 i h br i ck -
.

p ar ti ti o n s d F i g s 44 1 4 4,2 a n d 4 4
,
6 A ch am
. b e r 8 7 by ,
1 2 f t h as fo ur 8 ft .
,
.
,
-
.

1 2 i n doors 6 Fi g 4 39 for the r em

-
.
,
oval of dust
,
.
,
.

The di stri b uti on flue f Fi gs 44 1 and 44 2 whi ch i s 1 6 by 1 6 ft i s b ui l t of , ,

.
,
.
,

bri ck and cover ed wi th a j ack arch roof I t r uns along the enti re leng th of -
.

the b ui l di ng and i s co nnected wi th th e 1 6 ch am ,

b ers by means of 4 2 i n -
.

hi nged dam pers g Fi g 44 1 whi ch are made of V , , 4 i h s t

.e el s t i f
f en ed by ,
a ngl e -
.
,

i ro ns and operated thro ugh 2 in gas p i p e stem s -

.
-
.

DETAILS OF SUPPORT “ THE 0FT J TE L“Am E

DETAIL OF ROO F UPON TNE “ESL . Ull OlNO T8 000“

FI GS — Ba fil trati on Murray Utah

.
44 3 to 44 5 g
.
, , .

On top of the di stri buti ng

flue i s plac ed the ret urn flue, h, Fi g s 44 1 and 44 2 -
.

whi ch i s 1 1 by 1 6 ft and is co nnec ted wi th the 1 6 cha bers by 1 6 por ts, . m

k, Fi g 44 2 provi d ed wi th 34 ih hi ng ed d a p ers ; these O pen i nto th e ch a b ers,
.
-
. m m
and are op ened and clo sed by ch ai ns on th e th i ble floor The return flue, m -
.
-

h , Fi g 44 0, i s connec ted wi th the fan flue fro

. the blast f urnac es, i , Fi g s m .

44 0, 4 5345 ,
2 and prov i d ed wi th a da
,m p er by
i n or der
a sheet -
i ron down ta k e -

tha t the gases from any one of the ch am b ers cut out by means of valve g , ,

Fi g 44 1 to b urn accum
. ulated d ust m
,
ay p ass by por t 13 Fi g 44 2 i nto the fan , ,
.
,

and be di stri b uted wi th the blast furnac e gases i n the o th er cham bers .

In b urning th e dust i n a cham ber the door a Fi g 439 i s left Open to , , ,

.
,

furni sh the nec essary ai r .

The thi m ble floor 0 Fi gs 44 1 44 2 and 44 6 m ad e of NO 1 0 steel plate i s

-

, ,
.
, ,
.

1 5 ft 1 5 i n above the cham

. b er floor I t i s di vi ded as alr eady sh o wn i nto
. .
, ,

fo ur co mpar tments each of whi ch contai ns 1 008 steel thi mbles 1 7 in i nsi de
, , .

di ameter and 1 0 i n hi gh The thi mbles are mad e of N o 1 4 steel p late and are
. . .

ri veted to the steel floor Th e fil ter bags are sli p ped over th emand wi red . .
444 ME TALL URG Y OF LEAD

There are provi ded 4032 bags Fi gs 44 1 44 2

, .
, ,
—
44 7 44 9, i n th e fo ur com
p art mnts ;
e th ey are 1 8 i n i n di ameter and 30 ft lo ng
. . . They furni sh a fil tering
surface of sq ft whi ch fil ters
. . cu ft . .
gas p er mi n ; . cor

responds to sq .f c p er cu ft gas p er mi n When one com

ft . sur a e . . par t .

ment i s cut out for burning dust and fume i n the chamber there remain ,

avai lable sq ft fil teri ng surface p er cu ft gas p er m

. . in The basi s
. . .

for calcula ti ng the number of bags needed was 2 5 sq ft p er cu ft gas p er . . . . .

44 6 ME TALL URCY OF L E AD

furnaces ; later a 50 h p motor dri vi ng the fan at 80 r p m took the gases

-
. . . . .

fromsi x blast f ur naces The blast furnace gas arri ves in flue i and i s deli vered
.
, ,

i nto di str i b uti ng fl ue f at a p ressure of

, i n water ; j ust before sh ak i ng the
, .

bags the pressure rises to 94 i n The gas leaves a blast furnace through a sheet .

i ron goo se neck -

The gases fro mei gh t blast f urnaces pass thro ugh 1 057 ft
. .

of bri ck and 70 ft of sh eet i ron flue before they enter the fan house Thei r
.
-
.

av erage tem
°
perature i s 38 C and the SO; content p er c en
.t .

Roo t 1 Board and

FIGA SI S ECT ION

mace!

FIO A SZ
FIO ASS

FI GS .
4 5 1 to 4 53
— Bag filt rati on,
. Murray
,
U tah .

The flue -
llowed to accumulate i n a compar tm
d ust is a ent to a d ep th O f

not m ore than 2 4 in as wi th a grea ter dep th th ere i s danger of self i gni ti on
.
,
-
.

Wh en i t has atta i ned the permi tted th i ckness i t i s rea dy to be i gni ted and heap ,

roasted The com

.
p ar tment i s cut Ofl fro m th e di str i b uti ng fi ne and co nnec te d
wi th the return flue; the fro nt doors are Op ened and glowi ng coal i s spread over
-

the surface to ki ndle th e dust wh i ch b urns for 5 to 6 day s The heat generated
,
.

by the oxi dati on of carbon and m etalli c sulp h i de i s sufi ci ent to si nter a large

par t of the dust sufli ci ently to permi t i ts being handled by shoveli ng I t i s .

shov eled i nto wh eelbarro w s and sam pled at the same th e by fracti o nal
selec ti o n All laborers havi ng to work w i th dust are req ui red to tak e a sho w
. er
 S M ELTI NG LE AD OR E S I N TH E BLAS T F UR N A CE 447

bath after the work i s Over to change thei r clo thes and are forbi dden to eat
, ,

thei r m ea l s w i th d i r ty hands .

D uring 8 m onths Of 1 9 1 1 there were smel ted tons charg e; th ere

were recovered i n the bag ho use 1 1 2 4 tons fume 01 p er c ent of the , .

wei gh t of charge Table 1 03 gi ves the di stri buti on of metals i n charge and
.

fume and Table 1 04 par tial analyses of rawand sintered fum

,
e .

T AB LE 1 03 .
— D ISTRIBUTIO N or ME TALS 1N CH ARGE AND me
Fu :

Total mtal e s in charge smelted .

Total mtal e s in 1 1 24 tons f um e

recovered.

Per cent . mtal

of e i n charge re

co ver d i n fum
e e .

Oz per ton . Oz p er ton

. Per cent Pb . Per cent Cu
.

Assay of the 2 tons of charge

T AB LE 0
1 4 — Pu n “ AN ALYSE S or Ra wAN D SrN rE sE n F
'
m

The co st O f all Op e ati r ons of th e bag ho use for 4 years and 8 months i s gi ven
i n Table 1 05 .

T AB LE 1 05 .
— RE COVE RY or Fm ,
E rc , '
. AN D COST or, non E NTIRE OPE RATI O N or B AG H or e . s

J U LY 7, 1 907, 1 0 FE B . 2 9, 1 9 1 2

tons lb .

oz . oz . oz .
p er ton
oz . oz . oz .
p er to n

lb . lb .
3 2 .
4 per cent .

lb . lb .
448 ME TALL URG Y OF LE AD

Operati ng exp ense Outco me

Treat mnt
e charge 69 2 9 tons at

Moti ve p ower Op erating cost

Suppli es and repai rs
To tal cost

To tal . Value of metals recovered

Gai n for 4 years and 8 mnths o . 09

The state ment ho ws an apparent gain fromthe i nstalla ti on

i n Table 1 05 s

of the bag ho use i n 4 years and 8 months But the figure does not include .

i nterest on ori gi nal i nvestm ent nor a fair p ercentage for am or ti zati on If
,
.

these tw o th ings are i ncluded as they sho uld be the apparent gai n i s chang ed
, ,

i nto an ac tual lo ss as shown i n Table 1 06

,
.

T AB LE 1 06 — P1101
. “ AND Loss or OPE RATION
Gai n i n 4 years and 8 onths m
6 per cent i nterest on cost of $ 1
. for 4 years and 8 months 57
5 per cent . mortizati on for 4 years
a and 8 m
onths .
37

Net loss i n 4 years and 8 mnth

o s .
28

If the A8 20; in the fu me were recov r d the lo ss of

e e , would be
reduced by but there wo uld sti ll be a net lo ss of

FIG — Solenoi d shak i ng devi ce

.
4 54 . .

210Solenoi d Bag shaki ng

.
-
Devi ce
The bags i n a si lver lead s eltery — 1 -
m
are usually shak en once or twi c e a day by eans of a lever attach ed o utsi de of m
Bennet, Mi n
. E ng . World ,
1 908, xxrx , 633 ; E ng . Mi n . J .
,
1 908, Lxxx vr, 4 5 1 , 1 009 .
450 ME TALLURGY OF LEAD

contai n more 803 th an i s p ermi ssi ble i n bag fil tration are neutralized by ,

treatm ent wi th gro und l i me and z i nc o xi de i n the Spr ague proc ess ; the gase s

fro mthe blast furnaces are fil tered di r ec t A sketch of the fil ter ing plant is .

gi ven i n Fig 4 56 The roast i ng di vi si on contains Wedge roasti ng ki lns r

. .
, ,

o t ro aster s l and D wi gh t Lloyd si nteri ng m ach i nes g T h e ga ses fro mth e

p
-
.
, , ,

Wedge k i lns pass i nto flue j whi ch has at one end the li m e feed 3 ( see page
,
-

th e p ot t oasters deli ver th ei r gases i nto flue k whi ch i s pro vi ded ,

wi th the li m e feed t; bo th flues j and k ter m

-
i nate i n the m ai n flue whi ch

also rec ei ves the g ases fro m the D wi gh t Lloyd si nteri ng m

, , , ,

achi nes thro ugh -

FIG .
4 56
— Filteri ng p lant ,
. Mi dvale, U tah .

branches 0 p rovi ded wi th pl ug valves n whi ch control the amo unts of zi nc

, ,
-

, ,

o xi de prod uced i n the Wetheril l zi nc f urnaces p fro mblende concentrates , , .

The m ai n flue enters the fan ho use w hi ch has i ts li me feed i The gases ,
-

,
.
,
”
neutr ali z ed as to 803 p ass through cool ers g and goose necks g
’
,
i nto the , ,
-

, ,

di stri b uting flue g and thence i nto the roaster bag ho use f
, , ,
.

The g ases fro mthe blast f urnaces 6000 cu ft p er m i n arri ve i n the blast ,
. . .

furnace flue enter the NO 1 4 Si rocco fan a whi ch for safety i s pro vi ded wi th
, .
, ,

the li m
” ’
-
e feed b and then thro ugh flue d coolers d goose neck s d
, , and , , , ,
-

, ,
’
di stri buti ng flue d i nto the bl ast f urnac e bag ho use e
, ,
.

The bl ast furnace bag ho use i s shown i n Fi gs 4 57 and 4 58 I t i s 1 39 ft 5 i n . . . .

long 2 3 ft 2 i n wi de and 33 ft 6 i n hi gh The lower par t dust chamber B

,
. .
, . . .
,
 S MEL TI NG LE AD ORE S I N TH E BLAS T F URN ACE 46 1

is closed by bri ck walls ; the upp er par t bag chamber C i s a wooden frame
en , ,

wo rk wi th studs 2 by 8 i h at 35 i h centers and 2 by 8 i n gi r ts spaced for 8 ft

,
.
-
.
,
-
.
-
.

co rr uga ted i ro n wi th 6 i h laps whi ch i s nailed on the o uter si de The i nsi de -

.
,
.

i s lin ed w i th 36 i h asbestos sheets i n thi ck nai led wi th 1 i n lap s

-
. The ,
.
,
-
. .

i n cli ned outl et fl ue D i s of si m i lar construc ti on B o th studs and gi r ts are 2 by

, ,
.

6 i n and sp aced at 2 4 i n centers ; three si des are li ned w

. i th tongued and groov ed-
.

bo a r ds and the w hole i s encased wi th No 2 2 copper coated sheet steel I t ends

,
.
- -
.

a t t h e bas e of a self sustai ned bri ck li ned steel stack 1 6% ft i nner di am -

eter -

, .

a n d 2 1 0 ft hi gh . .

Fro .
4 57
— Blast urnace ba house
.
g , f M i dvale ,
U tah .

The thi of % 6 i n steel carri ed by 1 2 in I beams has 2 400

mbl e -
floor, -
.
,
-
.
-

t hi m b les 1 1 i n i n di ameter and 1 0 i n hi gh whi ch serve a corresp o ndi ng num

,
. .
,

ber of b ags 1 2 i n in di am eter and 34 ft long m

, ade of 4 2 i n canv as do uble
. .
,
-
.
,

sew ed wi th 1 i n lap s wi r ed at the bo t to m -

s and suspended at the top s from2 i n
.
,
-
.

i e wh i ch are k ep t i n p la c w i th by 6—i n p a c er
p p s , e 2 s s . .

The b ags have a fil teri ng surface Of sq ft whi ch wi th cu ft . .

, ,
. .

g a s p e r m i n corr es po n d s t o sq
. f,t ar e a p er c u ft as
g p er m i n . . . . .

The d ust ch am ber i s di vi ded by four walls i nto five co mp ar tments or bays ,

each provi ded wi th i nlet p i p e for ad m i ssi o n of gas and exh aust p i p e for creat -

,
-

i ng a vac uum ; bo th are co n troll ed by d i sk v a lv e s T h e bo t to m of a d u s t -

.

chamb er i s V sh aped wi th i ron si des placed at an angle of

-
In the tro ugh
i s a h eli cal screw whi ch i s connec ted by m eans of a clutch wi th a m
,
o tor dr i ven -

co unter shaft and deli vers the dust to the di scharge Openi ng of a bay placed
-

,
-

under t he di vi si o n wall whence i t drop s i nto a car , .

The blast furnace gases are coll ec ted i n the m ai n bri ck fl ue fro mwhi ch a ,

1 2 ft el bow lead s th emto a 1 2 ft b alloon flue 1 2 7 ft lo ng ( a Fi g 4 56) endi ng i n

-
.
-
.
,
.
,
.

t he fan ho use c wi th li m e feed b The g ases enter the di stri b uti ng flue thro ugh
, ,
-

,
.

a 7 ft p i pe and fromth i s enter the fi ve co m

-
.
p a r t m e n ts t o as c en d i n the b a g s .

The finely di vi ded li m e set tl es on the b ag s and fo rm s a p ro tec ti ve coati ng .

Leavi ng the bags the gases ri se to the top of the cham ,

b er are di rec ted down ,
452 ME TALLURGY OF LE A D

ward by deflec tors i nto flue D ( Fi g . thro ugh whi ch they travel wi th a

p d of 9 ft p er sec
s ee . .

Once a shi f t the i nlets i nto the d ust cham ber are closed and the exhausts
Op ened w hi ch co nnec t wi th the exhaust mai n x and thro ugh thi s wi th the , ,

balloon fl ue on the exhaust si de of the fan The pres sure i n the bags usually 1 .
,

to 2 i n w ater i s rep l aced by a sli gh t vacuum

.
, ; th e b ag s co ll ap se and loo sen th e

dust w hi ch has coll ec ted on them Abo ut 5 mi nutes i s allowed for the dust to
.

drop i nto the d ust chamber The operati on i s repeated two or three ti mes
. .

Thi s m ethod of detachi ng th e dust i s not as efi ci ent as sh aki ng by hand or

l B Alr

Fro .
458 — B . f
last urnace bag house, M idvale, U tah .

mech ani cal means prolo ngs the li fe of a bag as the al ternate deflati ons
,
but i t ,

and i nflati ons are less sev er e on the fil teri ng clo th Once i n several days th e .

bags are shak en by hand i n order to mak e up for the defici ency Any dust .

acc um ula ti ng on the V shap ed si des of the dust ch am

-
ber i s rel eased by j arri ng
wi th a h ammer or a bar .

The bag ho use for the roaster gases has the sam e co nstruc ti o n as th at of

the blast f ur nace di vi si o n The advantage of th i s co nstruc ti o n b esi d es i ts

.
,

lowcost of i s th at there i s li t tle co ndensati o n of m oi sture as co mpared

wi th a bri ck b ui l di ng and conseq uently less corro si on
,
.

The flue dust fromthe roas ter gases carri es 35 to 4 2 per cent Pb 9 to 1 6 p er
-
.
,

cent As and 1 0 oz Agp er ton I t i s bri q uetted the li me f urni shi ng the necessary
.
,
. .
,

bo nd and goes to the blast furnace charge The flue dust fromthe blast furnace
, .
-
454 ME TALL URGY OF LE AD

thro ugh i t roasti ng ch arge i s m

The ade up i n such a m anner that the roasted

thi s m
.

ore sh all show an alk ali ne reac t i on of not less th an 5 p er cent eans tha t .

there m ust be p resent i n the ore m ore than 5 per cent avai lable Cao when i t .
,

i s analy zed for Cao ZnO and S03 and wh en the CaO and Zuo are figured
, , ,

as b ei ng present as CaSO 4 and ZnSO 4 .

“
b l e. 9 Th rea ds
p er I nch

F1 03 .
4 59 and 4 60.
— Li m fe d
e-
e er, M i dvale , U tah .

2 1 3. Bag H ouse, General — Detai ls of the bagho uses at Mur ray and Mi dvale,
Utah , have been gi ven i n § 2 08 and 2 1 0 There are cer tai n features whi ch are
.

fo und i n every bag ho use and o thers whi ch are not contai ned i n the precedi ng
,

di scussi o n ; th ese are tak en up h ere .

All bag ho uses have a hor i zontal p arti ti on 1 2 to 1 6 ft abov e the m ai n floor
, .
,

whi ch di vi des the house i nto the upper filter chamber 30 to 40 ft h i gh and the ,
.
,

lo w er dust cham ber 1 2 to 1 6 ft hi gh The hori zontal par ti ti on or thi mble floor
,
. .
-

i s usually m ade of sheet steel but som

-
eti m es Of r ei nforced concrete as at Selby ,
,
 S MELTI NG LEAD ORE S I N TH E BLAS T F URN A CE

Cal .
l
carri es from3000 to 4000 thi mb les over whi ch are sli pp ed the bags
It 2

to be ti ed w i th twi ne wire or str ap clam p s T h e du s t ch a m b er i,s di v i de d i n to ,

-
.

a num ber Of compar tments or cellars each of whi ch i s connec ted thro ugh a por t , ,

provi ded w i th a closi ng valve wi th the gas m ai n The p ar ti ti on of every third ,

.

or fo ur th bay may reach to the roof or only to the thimble floor as do the ,
-

o th er s In the former case each filtering compar tment has a sep arate sheet iron
.
,
-

stack to carry ofl the filter ed gases ; i n the latter the gases fromthe enti r e ,

cham ber are drawn 05 thro ugh a single flue close to the roof leadi ng to the stack , ,
.

The m ore q ui ckly the gases are wi thdrawn the better for the li fe of the bags ,
.

A fan cap able of m ovi ng from to 2 cu ft gas p er m i n draws . . .

the gases fromthe f urnaces thro ugh cool i ng and set tli ng flues 1 000 to 1 800 ft , .

i n leng th and deli vers th emat a tem perature of about 70 C to a di stri b uti ng °
, .

fl ue fromwhi ch por ts extend i nto the cellars Of the bag house The pressur e
, .

Of the gas i s from1 to 2 i n water ; h i gher pr essur es gi v e gr eater filteri ng capac i ty .

,

but shor ten the li f e of a bag ’

.

The b ags 3000 to 4 000 i n num ,

ber are usually 1 8 i n i n di ameter and from30 , .

to 33 ft i n leng th . Th e filtrati on surface ofi ered i s abo ut 3% sq ft p er cu ft

. . . . .

g pa s er m i n ; i t do es no t go
. b elow 2 % qs ft ‘
a nd d o e s n o t ex c ee d 5 q
s f t I n . . . .

r egard to blast furnace tonnage i t i s the usual c ustomto p rovi de from300 to 500 ,

sq ft surf ac e p er ton charge sm

. . elted i n 2 4 hr At Mi dvale Utah there are .
, ,

provi ded 2 sq ft fil teri ng surfac e p er ton Of f um e coll ec ted p er day

. . .

The bags are m ade of co t ton and of wool Co tton clo th has from30 to 4 0 .

str and s p er li near i nch dep endi ng upon the charac ter of the f um e to be filter ed .

“
Accordi ng to Iles co tton bags beco m e sli gh tly co lor ed at 1 00 C but are no t
,
°
.
,

weakened ; sli gh tly brow ned at 1 2 5 C wi th str ength ap prec i ably al tered ;
°
.

much browned at 1 50 C and deci dedly weakened so as to tear easi ly If °

. .

i n contac t w i th aci d f um e of the fil tered gas at tem

°
p e r a t ur es Of 35 to 4 0 C th e .
,

clo th i s rapidly attacked .

Woolen clo th owi ng to the longer nap i s of a coarser weave than co tton 2 0
, , ,

s trands to the li near i nch ; i t retai ns i ts elasti c i ty at tem per atures as hi gh as

1 2 0 and 1 30 C and r esi sts sli gh tly ac i d f um Gases wi th a tem
° °
. es at 65 to 80 C .

p e ra tu r e of 1 3 2 C h av e b een sa fely fi lte

°
r ed W o ol.i s l ess a tta ck e d by a c i d th a n .

i s co tton and esp ec i all y wh en the wool i s allowed to retain i ts natural gr ease
,
.

When sco ured wool i s used i n the manufac ture of clo th the gr ease i s added ,

l ater Altho ugh a woolen bag at M urr ay (p age 44 5) cost nearly

. ti m es as

much as one of co tton the longer li fe of the former more than mak es up for the ,

extr a ex p ense .

Alexander m ‘
ade exhausti ve tests on the cri ti cal tem peratures Of co tton and
woolen bags H e found that the strength of co tton begi ns to decrease on ex
.

1 Bennet, E ng Mi n J , 1 908, uco rvr, 4 5 1 . . . .

D etails : Alexander, Tr A I M E , 1 9 1 4 , . . . . . x u x, 6
5 3 .

Anderson, Tr A I M E , 1 9 1 4 , x u x , 5 7 1 . . . . . .

Anderson, l oo . ci t .
, gi ves sq . ft .

“Lea d Smelti ng, 210

p . .

Tr A I . . . M . E .
, 1 9 1 4 , x ux , 561 .
456 METALL URCY OF LE AD

p osure of 4 8 hr to 1 00 C (see Iles above) wh ereas wi th a woolen bag the sam

.
°
. e , ,

A 1 hr trea tm ent begi ns to showi ts

°
tak es place o nly af ter 96 hr at 1 3 5 C . .
-
.

°
eflect on co tton at 1 2 6 C and on wool at The followi ng i s h i s sp ecifi
‘
.
,

ca ti on for woolen clo th : The wei gh t i s to average 1 2 oz per yard and the .
,

t ensi le str eng th i s to be not less th an lb per li near inch The t es t pi eces . .

are to be sq uar e 3 5 i n on a si de and p ull i s to be agai nst the wa rp

,
. . The , .

fabri c i s to contain not less than 85 per cent wool fiber esti m a ted by taki ng .
,

the di fl erence between 1 00 p er cent and the sumof grease di rt m oi sture

‘
.
, , ,

burrs and co t ton fiber and to be prac ti cally free fromvegetable m

, , a t t er of all

ki nds The weave i s to be 2 2 ends by 2 0 pi cks p r i nch

.
” e
.

°
At Pertulosa I taly 1
cu ft gas Of 70 to 80 C are fil tered through 1 o to
, ,
. . .

1 2 fr am es of 4 30 to 59 2 sq ft w i th ver ti cal threads of asbestos The co llect ed f um

. e . .

i s d i slo dged by releasi ng the tensi on Of the threads and vi brati ng th e fr am es .

Thi s fil teri ng m edi umof L B Fi ch ter appears to be bett er sui ted t han w ool . .

for gases of hi gher temperatures ( 1 50 to 2 00 C ) and Of grea ter aci di ty H ow °

. .

ev er asbestos i s not as resi stant to ac i d f um

, s as i s generally beli eved
e .

H angi ng and shaki ng of bags shows a vari ety of proc edure s Th e m ethods .

used at M urray ( page 44 5) and Tooele (page 4 2 2 ) for hangi ng repre s ent tw o

ch arac teri sti c examples of m odern pr ac ti ce .

“ A

N W anted Co mp lete
Frcs 4 6 1. and 4 6 2 — Bag shaki ng devi ce, Globe
.
-
W orks D enver Colo .
, ,

Shaki ng bags to di slodge adheri ng f um e used to be done by hand The .

men have to be protec ted agai nst fumes and gas by rubber sui ts helmets and , ,

sup p li es of co m p r essed ai r Shaki ng by h an d w hi le m ore efl ecti v e th an by an y .

,
‘

mechani cal devi ce has been gi ven up i n most plants as i t i s slow and a very
, ,

di sagr eeable pi ece of work The m echani cal devi ce i n use at M urray has been .

gi v en o n p ag e 44 5 .

The shak i ng devi ce of the Globe Works Denver Colo i s sim i lar to t hat in , , .
,

use at M urray In Fi gs 4 61 and . a rowof bags i s susp ended by hooks .

1
Mi n . J .
,
1 90 7, Lxxxr, 665 .

1
Al exander Tr A I M E . . . . .
, 1 91 4, e x, 568 .
4 58 ME TALL URG Y '
OF LEAD

for conver ter f um es ; at N ew ark N J for gases fromsi lver furnac es ; and , . .
,

a num b er of o ther places .

At Trai l B C 1
the wi re discharge and p i pe collec ti ng system ( m
,
. . ul ti pl e
,
- -

treater) fir st used at Garfield w ,

as i nstalled in 1 9 1 5 for the r ecovery of dust and ,

f ume from the blast roasti ng sm el ti ng and conver ting di vi si o ns A si d e , , .

vi ew and cross sec ti o n of the m ul ti ple tr eater for blast furnace gases are show
-
n
i n Fi gs 4 63 and 464 . The b ui ldi ng i s an elevated steel struc tur e wi th central .

concrete fi ne and si x tr eater sec ti ons on a si d e ( at present i ncreased to ni ne) -

.

A tr eater sec ti on has 32 grounded cast i ro n p i pes 5 i n apar t whi ch are 1 3 i n

-

,
-

, .
, .

out er and 1 2 15 i n i nner di ameter ( the largest prac ti cal size) and 1 8 ft long .
, . .

A pi pe has a central N o 1 1 cow chai n ( the N O 1 0 log chai n form erly used .
-
.
-

str etch ed and filled wi th dust) whi ch r ec ei v es a curr ent of to 0 3 am p a t . .

55 0 vol ts T h e pla n t tr ea ts.

p er m i n u t e cu ft g as of a tem p era t u r e . .
,

of abo ut 1 80 C whi ch travel wi th a veloci ty of fro m5 to 7 ft p er sec The

°
.
,
. .

clear ance under these condi ti ons i s not sati sfactory as the temperatur e is too ,

hi gh and the veloci ty too great I t i s the intenti on to reduce bo th th e latter

,
.
,

to 4 ft p er sec The pi p es are expo sed to the ai r whi ch causes the outer sec
. .
,

ti o ns of th e p i p e to be cooler than the i nner As thi s i nterferes wi th .

uni form i ty of work the app aratus i s to be i nclosed , .

The gases arri ve fromthe blast furnaces i n the central concrete flue From .

th i s por ts l ead i nto the hopper sh aped bo ttom

,
s of the sec ti ons whi ch act as -

recei vi ng and di stri buti ng chambers The dust adheri ng to the pi pes i s di s .

lodged at stated intervals by tapping the pi pes wi th a hammer ; i t collec ts in

the steel hopper s and i s discharged fr equently so as not to red uce the vol um , e

Of the r ec ei vi ng cham ber The purified gases enter two balloon flues whi ch .
,

are com bi ned i nto a si ngle flue leadi ng to the stack I t i s the i ntenti on to con .

neet each tr eater cham ber separately wi th the m ai n exi t flue so as to perm it
close regulati on of the speed of travel by m eans of dam pers The req uire .

ments for sati sfactory work appear to be uni formi ty of volume temperature ,

speed (4 ft p er sec and less) and com

,

. posi ti on of gas and of amount of suspended

.
, ,

par ti cles Any change i n these five condi ti ons requi res speci al adj ustm
. ent

e coll ec ted i n the tr ea ter i s m

.

The f um ainly lead sulphi de wi th 60 to 70 p er cent

'

Pb .

work of Garfield has been noted on page 4 1 5

The .

At the Tooele plant the m ul ti ple pr eci pi ta tor treats p er mi nute cu , .

ft gases fromthe D wi gh t Lloyd si nter i ng m

. achi nes i n 880 p i pes 1 2 i n i nner -

, .

diam eter and 1 5 ft long ; the speed of gas i s 4 3 ft p er sec ; the tem per atur e i s
. . . .

governed by the am ounts of arseni o us oxi de present .

The m ul ti pl e treater of the Balbach Sm el ti ng and Refini ng Co Newark .

, ,

N J is sm
. all as i t i s r eserv ed for the gases fromthe si lver f urnaces
.
, ,

Attenti on m ay be call ed to the elec tr i c preci pi tati on of f um e at the works

of the Rari tan Copper Co Perth Amboy N J H ere the anode mud from .
, ,
. .

1
Guess, Canad . Mi n . J .
, 1 91 5, xxxvr, 37 .

Ann Report for 1 905,

. Mi ni ster of Mi nes Victori a , ,
B C,
. . 1 9 1 6, 5, p 79 . .

Pri vate notes, 1 9 1 6 .

S MEL TI N G LE AD ORE S I N TH E BLAS T F UR N A CE
460 ME TALL URCY OF L E AD

the l c troly ti c copper refinery af ter havi ng been freed fro mcopper i s melted
ee , ,

and fire refined i n r everber atory f ur nac es

-
The f um e laden gases are scr ubbed .
-

and th en draw n thro ugh tw o elec tri c preci p i ta tors placed i n ser i es
1
.

2 1 5 W et Condensati on
.
1 — In the collec ti on of flue d ust and f um e by w et .
-

methods the gases have been drawn through water and forced thro ugh one or
,
1
,

more hori zontal fil ters provi ded wi th sp rays of water whi ch carri ed down dust
‘

and condensed vap or They have been drawn th rough wetted towers filled w i th .

coke pebbles brushwood faggo ts etc or provi ded wi th hori zo ntal sta ggered
,
5
, , ,
.
,

shelves
“ or mounted wi th gable shaped sheets of lead 7
Sprays of w a ter have -
.
,

been i ntroduced i nto the current of hot gas i n amo unts sufli ci ent to formmi st
or fog whi ch woul d cool the gas and saturate floati ng par ti cles so that they m i gh t
set tl e w hen subj ec ted to speci al cooli ng i nfluences N one Of th ese methods
8
.

have been sufli ci ently effec ti ve to warrant thei r use in lead plants i n th e Uni ted
States .In E urop e on the o th er hand w 9
et cond ensati on i s not unco m mon “ , ,
.

The f ac t i s that whi le w et m ethod s can and do r em ove dust fromgases almost
comp letely th ey are not efli ci ent wi th f ume The Feld gas washer e g has
,
11
.
,
. .
,

recovered i n a lead p lant 99 p er cent of the dust They are co mmon wi th i ron . .

blast f urnaces for freei ng gas fromdust ; wh ereas dry fil trati on and elect r i c
11

preci p i tati on are at present th e onl y efl ecti ve metho ds avai lable for f ume
2 1 6 Treatm
.

. ent Of Flue dust

11 —
The q uesti on of the b est m anner Of r ecov er -
.

i ng values fromflue d ust wi th li t tle lo ss and co st i s di fi cult to answer as th e -

tr eatm ent i s governed by a v ari ety of condi ti ons .

The treatm ent of fl ue d ust fro mthe ore h ear th h as alr eady b een di sc ussed - -

and There rem ai ns to be co nsi d ered the d ust fro mblast f ur nac es

and fro m roasti ng blast roasti ng reverb eratory and conver ti ng fur naces , , ,
.

Blast f ur nace d ust i s li kely to co ntai n m etal li c sulp h i des and carbo nac eo us

matter ; dust fromfurnaces i n whi ch oxi diz i ng Op erati ons are carri ed on i s com
1
H of man
Metal lurgy of Copper 1 9 1 8 p, , ,
.
51 8 .

1
French E ng M i n J 1 880 xxrx 4 9 84
,
. .
, , ,
.

Il es S chool M i n Quar
,
t 1 —
89 5 9 6 x vn 1 03 .
, , ,
.

1
E ilers Tr A I M E 1 8 74 75 In 3 1 0
,
— . . . . .
, , ,
.

“
‘
Percy, Lead
, 8 70 , p
1 .
442 .

Falliz e, Rev Uni v M i n . . .

, 1 86 2 , xx, 36 7 .

“
Il es ,
loc . ci t .

7
Ri ch ter, Frei berg J ahrb , . . 889, p 57
1 . .

Berg H zlttenrn Z 890, xu x , 1 2 9

‘

1 .

m
. . .
,

E ng Min J
8 0
9 , x x 1 1 9 6
m7
.
. .
,
.
,

Dooli ttle -
Jarvi s, Tr A I . . . M . E .
,
1 9 1 0, x ,
09 .

1
Ferrari s, Oest Z t Berg H zlttenw, 4 55 ; E ng Mi n J 783 ,
‘

. . . . 1 905, . . .
, 1 90 5, Lxxx, at

Monteponi Sardi nia ,

.

Wynne op ci t 1 909 ,
. .
, ,
Lxxxv nr, 60 2 , at N eudorf, H arz Mountai ns .

1
H eberlei n F M etall
, , 9 1 3 , x , 7
1 6 . . n . E rz , . 1 .

1°
England : Roesi ng, Zt Berg H il tten S al W i Pr, 1 888, xxx vr, 1 03 Austri an Rep ort . . . . . . .

of the
“K K Arbei tsstati sti sches A t i
. H andes i ni st eri u
.
”
upon
“Blei vergi tungen i n m m m m f
m
H ut ten anni schen und Ge erbli chen Bet ri eben, H Older, i enna, 1 905 1 9 1 3, p ts 1 —
— 8 w V . .

11
M et Chem E ng . . .
,
1 9 1 2 , x , 4 36 , 1 9 1 3, xx, 399 .

11
H of man “General Metallur ” 1 1 8 86
gy, 9 , 4
m74
.
,

11
Iles, E ng . Mi n J . 1 886, x , , 93, 1 4 8.
4 62 ME TALLURO Y OF L E AD

not act well H ence more li me wi ll be requi red for blast furnace dust than for
.

roaster dust Goi ng a step fur ther the bi ndi ng p ower of li me for ro aster dust
.
,

wi ll be abo ut the same as that for rawore Of the same degree of fineness and
co ntent of sulp h ur as Of course pyri ti c ores ri ch i n sulphur e g concentrates
, , . .
, ,

canno t be bri ck ed b ecause upon heati ng they wi ll fly to p i eces If th en ore

, .
, ,

crushed to pass a li m i ti ng si eve Of say 2 m esh es to th e li near i nch be m i xed i n

wi th fine ore and flue d ust the addi ti onal advantage i s gai ned of th e angular -

shap e of the crush ed ore w hi ch wi ll requi re less li me for b i ndi ng and wi ll dry ,

more sati sfac torily on account of the mass Of capi llary sp aces between the crush ed
dry ore the m o i st flue d ust and th e creamli ke bi nder W hen the bri ck i s
,
-

,
-
.

bei ng dri ed ei ther i n the open ai r under sheds as at E l Paso Texas or addi ti on
,
1
, ,

all y ln a hea ted ch am ber i t wi ll gi ve up i ts water readi ly and on account of ,

i ts poro si ty shri nk wi thout crack i ng When charged i nto the blast furnace .
,

part of i t wi ll agai n fall to pi eces but to a much smaller extent than if the flue ,

dust had been bri ck ed alo ne w i th a hi gh p ercenta ge of li m e If the dri ed bri ck .

,

b efore ch argi ng i nto the blast f urnace i s b urned i n a ki ln i t w i ll wh en the , , ,

t em p e ra t ur e h a s b een r a i sed t o th e po i n t w h er e ca rbo n a n d s u lph i d e s b e g i n t o

ro ast b urn readi ly and the heat generated wi ll cause the lead or matte to cement
, ,

together the si ng le par ti c les of a bri ck to a soli d m ass Thi s gi ves the explana .

t i o n for the present prac ti c e of bri cki ng fine si li ci o us or es w i th fro m 2 to 5

p e r c e n t or o n t h e. av,
e r a g e 3p er c ent of s la k e d li m e an d 2 0 p e r c e n t or m or e .
,
.

of flue d ust to fri t together the si ngle parti cles when exposed to heat Wi th ores
-

,
.

havi ng a clayey gangue or wi th roasted ore or ro asted matte no addi ti o n of , ,

flue d ust i s necessary if the bri ck s be ki ln burned ; they w

-

, i ll fri t togeth er for m -

i ng so li d bri cks and Often as m uch as 50 p er cent of the S of th e rawm ateri al .

wi ll have been eli mi nated Wi th si li ci o us ore free fro msulp hur fro m2 to 3 .
,

e r c n t fi n e c o k e i s add ed to th e m i x t ur e t o f u rn i h t h e f u e l n e c e a ry for
p e . s ss

b urni ng i n the ki ln .

The bri cks consi sti ng of si li ci o us ore and flue d ust wei gh abo ut 8 lb api ece -
.
,

those fro mro asted sulphi de ores or m atte abo ut 1 2 lb .

I n ord er to bri ck ores sati sfac tori ly and cheaply wi th a sm all p ercentage

of l i me i t i s necessary to subj ec t themto pres sure whi ch requi res machi nery
, , .

Of the di fl erent form s of bri ck pr esses wh i ch have been used t he Ch i sholm , ,

Boyd and Whi te M i neral Press i s the m

,
1
ach i ne that has outli v ed the o th er s i n

lead p lants The mai n par ts of thi s machi ne, shown i n Fi g 4 65 are a roller
. .
,

mi ll and a moldi ng di sk The p an of the mil l i s 7 ft i n di ameter and i s li ned in . .

the pa th of the rollers wi th chi ll ed i ro n pl ates ; the roll ers are 4 8 i n i n di am eter .
,

have a 1 0 i h face are provi ded wi th removable chi lled i ron ri ngs and wei gh
-
.
, ,

5 000 lh ; a cro ss
. b e am k e y ed t o t he dri v i
-
n g sp i nd l e ca rr i es a plow a t e i th er e nd
whi ch turns over the bri cki ng mi xture frombo th si des Of the roll ers i nto thei r
paths The mold di sk i s a cast i ron p late 5 ft i n di amet er and 2 14 i n thi ck
.
- -

,
. .
,

havi ng two rows of ci rcular holes or molds ( 4 i n i n di ameter at the top and .

1 Vai l Mi n J 1 9 1 4 x cvm 4 6 5
,
E ng . .
, ,
.

E aster Tr A I M E 1 9 1 5 LII 7 2 1
, . . . . .
, , ,
.

1
Chi sholm Boyd and W hi te Co Chi cago , ,
.
, , Ill .
 S MEL TI NG LE AD ORE S I N TH E BLAS T F UR N A CE 4 63

sli gh tl y larger at the bo t tom ) pi vo ted at the center I ts m ovement i s eflected

, .

by a radi al arm journaled at the center and attached at the o uter end to a
p i tma n co nnec ted wi th a crank gear The armhas a ro und steel pawl whi ch -
.
,

dro p s i nto one of the holes and tw o plung ers As i t i s p ulled forward the p awl
, .
,

dra ws the di sk around 1 5 and the pi tm an forces the tw

°
o pl unger s i nto the

molds p ushi ng out a pai r of bri quettes on to a slow moving endless belt When
,
-
.

th e crank gear agai n reach es i ts first po si ti on the p aw

-
l drop s i nto the next hol e , ,

and th e pl ung ers force out a seco nd pai r of bri q uet tes and so on The m ovement .

of ro llers and di sk i s so adj usted that the rollers wi ll travel 2 0 ti mes over a
p a i r of m olds d uri ng th ei r p assage thro ugh the p a n th us fir m ly co mpr essi ng ,

th e fl ue d ust m -
i xture .

Fro 4 65
.
— Chi shol. mBoyd and Whi te p ress
, .

T he machi n
occup i es a floor sp ace 9 ft 6 i n by 1 1 ft 6 i n and i s 6 ft 2 i n
e -
. . . .
,
. .

hi gh ; i t wei ghs lh requi res a 2 8 h p engi ne and has a cap aci ty of 4 2 00

.
,
-
. .
,

bri cks ( 4 by 2 14 i n ) p er hr I t requi res two men at the p an fro mtwo to

. .
,

fo ur carri ers to remove the bri cks and one forem an , .

T he green bri cks recei ved fro ma m achi ne are loaded on bri ck tr uck s and ,

t h en pi led up rarely i n racks co m

,
monly on a covered floor to a hei ght of about
, ,

1 0 ft. and are ai r dri ed for fro m 2 to 3 w

-
eek s D ryi ng cham bers are of .

rar e occurrence wi th Western smel ti ng works altho ugh the bri ck fro mthemare ,

much harder than if si mply ai r dri ed ; wi th smel ti ng works located i n a less dry
-

at m o sph ere the dryi ng cham bers m ay be necessary esp eci ally duri ng t he cold ,

season .

Th eburni ng of the bri ck i s carri ed on in the ordi nary up draft ki lns common -

for b urni ng red bri ck T he bri ck are set up i n arch es abo ut 30 co urses hi gh t he
-
.
,

arches b ei ng 2 0 ft lo ng and the Op en por ti o n abo ut 9 co urses hi gh

. Si x or more .

arches are b ui l t si de by si de -
A ki ln 80 ft lo ng 1 0 ft wi de, and 2 0 ft hi gh wi ll
. .
, . .
464 ME TALLURGY OF LE AD

ho ld abo ut bri cks Fi res are bui l t i n the arches cordwood bei ng com .
,

mouly used It takes fro m3 to 4 cords to fire a ki ln The ki ln begins to burn

. .

after a fewho urs Of firi ng w hi ch must then cease I t bur ns for 2 or 3 days , .

and i s p ulled do w n after i t has b een gi ven som e ti me to cool Burni ng bri .

q uet t es i n kiln s was i n op erati o n i n 1 0

9 5 at B rok en H i lls N S W 1
, . . .

The bri cki ng of flue d ust whi ch w i th hand labor and a large percentage -

,
-

of li me co st formerly abo ut $ 2 a ton has been red uced by the use of m ach i nery ,

to fro m to a ton excl udi ng the co st of th e li m e , .

Li m e has prob ably to day r eplac ed all o ther b i nders H arbordt substi
1 -
.

tuted clay Church used p an sli m

1
es o thers h ave been succ essful wi th c em
, ent ,
.

Very sati sfac tory bri ck have been m ade by Carpenter

‘
wi th the waste
molasses of sugar plantati ons I ts composi ti on i s shown by the followi ng table ” .

i n percentages :

O O O O O O O O O O O O O O O O O O O O O O

The pri nci p ally li me and co nta i ns so me po tash Accordi ng to

ash is .

“
Stubb s the f uel val ue i s 37 p er cent of that of average Pennsylvani a bi tu
,
.

mi nous coal (H ; O V H C F C ash calorific po wer .

-
. . .

3 577 Ca l p er lb or . 1 lb m ol a sses e q u a l s a bo
. u t lb coa l . . .

3 F
.u si on — P r evi o us to th e i m prov em en ts m ad e i n b r i ck i n g th e co mm o n ,

method of treatment was to mel t th e flue dust i n a speci al reverberatory furnace -

or i n the f use box of a hand roasti ng f urnace where i t was added in quanti ti es
-

of say 1 00 lb to the roasted ore I t was charged before the ore was drawn fro m
, , . .

th e roasti ng h ear th and w as th us covered by the roasted ore so that li ttl e

-

, ,

metal was carri ed Ofi mechani cally It helped to si nter the charge but there .
,

was consi derable loss i n lead al though li ttle i n si lver M urray found th at ,
.

rem ovi ng the finely di vi ded carbon by washi ng assi sted the fusi on .

A charge of 1 50 tons of blast furnace flue d ust tak en fro mthe first 400 ft -
.

of th e dust ch amber of the Globe Smelting and Refini ng Co gave accordi ng to

-
.
,

I les : SlO;
7
Fe CaO Pb Zn S p er c en t A g a n d .
,

Au oz p er ton Af ter fusi ng i t had changed to Si O; Fe . 03 0 ,

Pb Zn S p e r cen t A g a n d A u o z p e r t on .
,
. .

1
Greenw ay E ng M i n J 1 905 n or m 73 , . .
, ,
.

1
Pri vate co mmuni cati on ,
1 89 1 .

1
E ng . and Mi n . J . 1 885, X L, 1 24 ; Tr A I . . . M E . .
,
—
1 886 8 7, xv, 61 1 .
,
‘
Op . ci t .
, 1 900, xxx , 768 .

1
Uni ted States D ep art mnt of Agri cultu
e re, Bullet i n N o . 1 8, tables 53 and 53 bi s, 2 5.
1
The Loui si ana Planter and S ugar Manufacturer j uly 1 3 , ,
1 805, 2 5 .

1
Pri vate co mmuni cati on , 1 89 7.
466 ME TALL URCY OF LE AD

th at cer tai n slags have especi ally if they co ntai n Fe; 0; Thes e ac ti ng upon , .

the sulphi des set free SO ; whi ch adheres to pell ets of m at te and hi nders them
,

fro msettli ng .

The quanti ty of by produc ts (spei ss m atte flue d ust) for m -

ed h as an i m , ,
-

por tant i nfluence on the outp ut Of Pb and Ag as they have to be ret reated ,

whi ch causes an unavo i dable loss i n metal It i s diffi cul t therefore to gi ve an

,

.
, ,

average fig ure of the Pb and Ag recover ed i n sm el ti ng i n the blas t f urnace

ay be sai d that a to tal lo ss of fro m6 to 7 p er c ent Pb represents v ery good

.

It m .

work wi th clean ore the lead assays bei ng made i n the dry way As lo ng as the , .

loss does not exceed 1 0 p er cent the work m ay be co nsi d ered sat i sf ac tory .
, .

Th e repor t to the Treasury Departm ent Of the Uni ted S tates by H ofm an
l

deali ng wi th the loss i n Pb prevai li ng at sm el teri es trea ti ng for ei gn or es has ,

shown th at the loss i n Pb vari ed fro m5 or 6 to as m uch as 2 0 p er cent A .

deci si o n of the Treasury D epar tment allo ws the works of the Ameri can Smelt
1

i ng and Refini ng Co at M aurer N J a loss of 2 0 p er cent and t hose at El .

, , . .
, .
,

Paso Texas
, p e r c
,
en t T h ese la rg e lo sses a r e ca u s ed by th e t r.ea t m e n t of
l ead ores ri ch i n As and Zn .

Wi th si lver the yi eld i s generally from98 to 99 p er cent the sil ver ass ay
1
.
,
-

being made in the dry way and not corrected Wi th losses of Pb rea chi ng 20 .

p er c e n t t he .yi eld i n A g i s low er t h an 8

9 p e r c en t ; th e d e crea s e d yi eld of .

Ag how
,
ever does not corr espond w ,
i th th e i ncreased loss of Pb but i s a great ,

deal less .

The yi el d i n An is 1 00 p er cent the Au b ei ng pai d to oz p er ton; .

, .

of ten there i s a plus gold .

The cost of sm el ti ng i n the Rocky Mo untai n di stri c t where blast roasted

4
,

ore i s largely used i n prepari ng the charges ranges fro m to p e r to n ,

charge p rovi ded the plant i s large and has all of i ts furnaces i n Oper ati on If
,
.

conver ting blast furnace m at te be i ncl uded the co st m ay ri se to p e r t on ,

charge Wi th a sm
. all p lant the co st of treatm ent i s appro xi m ately do uble that

of a large plant Of the to tal co st labor acco unts for about 2 3 p er cent ;
1
.
,
.

coke 40 ; coal 5 ; l i m
, esto ne for cok e ash 5 ; m
,
ai ntenance and repai r 5 ; delays -

, ,

caused by acci dents stri k es etc 5 ; flue d ust recovery 2 ; adm , i ni strati on
, .
,
-
, ,

7p er c en t .

1
E ng . Mi n J 9 1 1 , x cr,
. .
,
1 1 1 9 3.
1
Op ci t , 1 9 1 3, x cv, 53 2
mm 3
. . .

1
Iles, E ng Mi n 1 899 , J 0 7, 34 0, 36 7 .

m
. .
,

Godshall , op ci t , 1 900, , . . ax 4 3 .

1
Fi nlay, Mi n S c Press, 1 908, XCVI , 2 2 ; E ng
. . . Mi n . LXXXV,

Adki nson, op ci t , 1 908, Lxxx v, 99 2 . . .

Brownlee, loc . ci t .
,
1 1 10 .

Grabi ll, o p ci t 1 08
9 , rx xxvr 73
mm 6
.
. .
, ,

I ngalls, lac 5; . ci t .
, 31 Mi n . I nd .
,
1 90 8, , 08 .

m
Gui ter an, E ng Mi n J 1 90 8, Lxxxvr, 960 . . .

Austi n, Mi n S c Press, 1 9 1 4 , crx, 1 70. . .

 CH APTE R X

DES ILVERIZATI ON OF LEAD BULLI ON

‘

2 1 8 Introducti on
.
—The final separati o n of sil ver and . lead i s usually acco m
p li shed by the process of cupellati on ( 52 7 Up to th e i ntrod uc ti o n of the
Pat tin so n p roc ess all argenti ferous lead w as c upelled ; but thi s has

many di sadvantages promi nent among whi ch are the cost and th e loss i n metals
, ,

th e l i mi t bei ng very soo n reached where the separati on of lead and sil ver ceases to
be econo m i cal Thi s i s the case wi th lead b ulli o n assayi ng abo ut 30 oz Ag p er
. .

ton . Below thi s am ount the si lver recovered wi ll hardly p ay for the labor fuel , , ,

and m ateri al req ui red the loss i n m etal and the i nferi or gr ade of lead ob tai ned
, ,

fro mthe reduc ti on of li tharge I t beco mes necessary to concentrate the si lver .

i nto a sm aller am o unt of lead before cupelli ng The process of Patti nson w i th .
,

i ts m odi ficati ons and Of Parkes do thi s successf ully

,
.

The p rogr ess m ad e i n d esi lveri z i ng i n the dry way d uri ng the last 80 y ears i s

well i ll ustr ated i n Table 1 0 7 The figures p ubli shed by H er mann are de l
.

ri ved fro mthe ac tual worki ng resul ts ob tai ned at th e E ms Smel t i ng and Re
fini ng W orks Prussi a w here the three proc esses were used one af ter ano ther
, , .

To these have b een added the am ount of lead to be c up elled and the traces of
gold .

T AB LE 1 07 .
— CO MPARI S ON or CUPE LLATION , PATTI NSON , AND PAxxE s PROCESSE S

Cost
m
A ount of lead to be cupelled
Loss i n lead and silver
Imp uri ti e remai ni ng i n the lead per cent
s ,
. .

Si lver rem ai ni ng i n the lead o unces per to n ,

.

T races of gold

peri mented abo ut 1 890 wi th the oxi dati o n

At Tar nowi tz , Si l esi a, Roesi ng 1
ex

of lead i n a basi c li ned converter H e work ed w i th charges of l ead w ei gh i ng

-
.

lb and assaying from

. to oz Ag p er ton ; the f um es wh i ch he .

coll ec ted assayed 75 p er c ent Pb and 2 5 oz Ag p er ton H e also refined . . . .

,

by a few mi nutes blo wi ng desi lveri zed zi nc b eari ng lead ,

-
.

1
B erg H al leu. mZ . .
,
1 883, x m 38 ,
2.

1
Rev Uni v M i n ,
. 89 2 , xvrr, 1 1 0 ; B erg H uttenrn Z
. . 1 . . .
, 1 89 2 , L1 , 1 0 2 ; E ng. Mi n J
. 1 89 2 ,
43 ;
1 S tahl u E i sen, 1 8 2
9 , xn , 3
.
70 .
468 ME TALL URGY ’
OF LEAD

I n 1 878 Kei th 1
rted exp eri ments wi th the elec trolysi s of lead b ulli on wi th
sta

lead acetate as elec troly te and lat er b uil t a plant whi ch

, however was no t , ,

successful .

I n 1 906 Ta mma i i ssued a pamp hlet

pparatus for
s
2
i n whi ch he di sc usses hi s a

th e elec tro ly ti crefini ng of lead whi ch consi sts Of a r evolv i ng metal di sk h alf ,

im mersed i n an elec trolyte made up of soluti ons of acetates of lead and p o tas
si um The spongy c athode lead i s to be scr ap ed ofl m
. ech ani cally wash ed , ,

co mpressed and melted and th e anode mud work ed by so me process N o th

, , .

i ng m ore has been heard abo ut thi s process .

Later abo ut 1 90 2 Bet ts elec trolyzed lead b ulli o n wi th lead fluosi li cate
, , ,

ac i d i fied wi th fluosili ci c aci d as elec t roly te Thi s p roc ess i s consi der ed , .

i n § 2 90 .

The task of m odern desi lverizi ng (or refini ng) works i s not onl y to Separate ,

efl ecti vely and cheap ly the pr ec i o us m etal s fro mlead but also to m ak e out of a ,

lead bulli on contai ni ng from95 to 98 p er cent Pb a refined lead of not less than .

p er c ent Pb an d sa l able prod uc t s of t he.i mp uri ti es co ntai ned i n i t such as ,

Cu, Sn, Bi , As, and Sb .

followi ng pages th e four standard processes for desil veriz i ng lead

In the
bulli on wi ll be di scussed i n the order : Patti nson p rocess Park es process , ,

Cupell ati on process Betts process Cup el lati o n follows the processes of ,
.

Patti nso n and Park es as i t has c eased to exi st as an i nd ep endent process , ,

havi ng become an auxi li ary to the o ther two .

PATTIN SO N PRO CES S

2 1 9. process i s based upon the fac t

Patti nson Process, General .
L -

T hi s ,

di scovered by H ugh Lee Pat ti nson i n 1 833 that if lowgrade lead b ulli o n i s ,
-

melted and then cooled to i ts freezing poi nt crystals of lead wi ll separate whi ch -

are m uch poorer i n Ag than the ori gi nal lead If t h ey are rem oved and the .

process i s repeated always addi ng fresh lead of the same tenor i n Ag a large , ,

q uanti ty of mark et lead lowi n Ag wi ll resul t and a small amo unt of enri ched ,

lead ready to be cup elled By the rep eated mel ti ngs and crystalli zati ons .

necessary m any of the i m p uri ti es,wi ll be coll ec ted i n dro sses and th e mark et ,

lead beco me correspo ndi ngly p uri fied .

The explanati on of th i s phenom enon w hi ch formerly was not understood , ,

became clear wi th the ap pli cati on of the laws of sol uti o n The freez ing p o i nt .
-

curve of the alloy seri es Pb Ag has been gi ven i n Fi g 1 1 Wi th Pb soli difyi ng

— . .

° °
at 3 2 7 C the eutec ti c of Pb Ag wi th 2 5 p er c ent Ag i s seen to freez e at 300 C
— .
,
. . .

If a lowgrade fused alloy of Pb and Ag i s co nsi dered as a di lute sol uti on of Ag

-

1
E ng . Mi n . J .
,
1 8 78, xxvr, 2 6, 59 ; 1 88 2 , mm , 29 2 ; 1 883, roo m , 3 72 . Tr A I
. . . M . E .
,

1 88 2 , x, 3 1 2 ; 1 884 —8
5, x m3
,
10 .

Ha mpe s ’
cri ti ci s m Zt . B erg H utten S al
. . . W i . . Pr , . 1 88 2 , xxx , 8 1 ; E ng . Mi n J . 1 88 2 ,
m
,

xxx , 1 44 .

“E le
1
ctrolyt i c Process for the E xtracti on, Sep arati on and Refini ng of Metals , Pari s,
1 906 : Mi n . I nd .
,
1 906 , x v, 54 3 .

“
1 Percy, M etall urgy of Lead, London, 1 8 70 , p . 1 3 7.
470 M E TALLURGY OF LE AD

about cent but there i s no indi cati o n of thi s i n the

10 p er .
, g c urv e F i g 1 1 Pb A
—
,
.
,

and t he Pb Au c urve Fi g 1 2
—
,
. .

Junge fo und at Frei berg Saxony

1
, ,

that th e ri cher the Pb i s i n Ag th e ,

more easi ly wi ll the Bi be co ncentrated

i n it Thus lead b ulli on wi th .
,

oz Ag p er ton and p e r c en t B i. .

gave ri ch lead wi th oz Ag p er .

ton and p e r c e n t B i a n d m a rk e t .
,

lead wi th oz Ag p er ton and .

pe r c e n t B i W h en th e le a d . .

b ulli on was ri cher i n Bi the Ag ,

remai ni ng the sam e the ri ch lea d ,

retai ned more Bi p e r a n d

thi s w as also the c ase wi th the m ark et

lead p er

H ow slowly th e Bi co ntent of th e -

crystalli z ed lead di mi ni sh es i n Pat ti n

soni zi ng if co m pared wi th the Ag i s , ,

sho w n i n Fi g 4 66 The curv e A B . .

1 3 8 4 5 6 7 8 9 10 11 12 18 14 15
r e f er s to a l e ad b u lli o n co n ta i ni n g
K tt l fi
e e o .

p e r c en t B i t he c u rv e C D t o on e .
,
Fro 4 66 — D ecrease O f Ag and Bi in
.

w i th c t T h d cr of
.

5 p e r e n e e ea s e
Pat ti nsonizing
.

Bi i n a seri es of cry stalli z ati ons carr i ed

out wi th the m ethod by thi rds i s shown i n Table 1 09 ; the figures i ndi
cate the percentages of Bi .

TAB LE 1 09.
— BE H Av1 0R or E 1 1N PATTTN S ON PROCE S S

Le a d b e f o r e o 2 4 2 0 2 05 0 2 00 0 2 03 0 1 83 0 1 73 0 1 62 0 137 0 132 0 1 10 0 1 05 0 08 8

cryst al li zi ng

R esul ti ng crys o 2 3 5 0 2 07 o 2 04 o 2 08 o 1 7 6 0 1 58 0 1 57 o 1 28 0 1 15 0 1 1 2 o 08 5 0 07 4 0 07 0

t ale .

Resul ti ng li q uid o 2 9 0 0 2 4 7 o 2 4 3 o 2 4 2 0 1 8 1 o 2 1 7 o 2 1 2 0 1 83 0 1 7 4 0 1 4 0 0 1 3 0 0 1 0 1 0 09 2

lead .

( a) Mark et lea d .

of Bi i n Ag free Pb i s tak en up wi th the Tredi nni ck process i n

The b ehavi or -

5 4
2 2 O f t
.h e metals co m m o nly fo und i n l ead b ull i o n S b Bi and N i a re co nce n , , ,

trated i n th e li qui d lead ; As i n the crystals ; Cu w hi ch has not been rem oved
wi th the dross remains equally di stri buted in the two p roduc ts
,
.

The proc ess Of co nc entr ati ng the si lver i n a sm all am o unt of lead
may be conducted accordi ng to two systems called the M E TH O D B Y TH IRDS ,

and the ME TH OD B Y E I GH TH S I n the first of these system s two th i rd s of t he

.
-

1
Frei berg J ahrb 1 89 5 3 ; Mi n I nd 1 89 6 v 39 7
. .
, ,
. .
, , , .
 DE S ILVE RI ZA TI ON OF LEAD B ULLI ON 471

lead contai ned i n the ket tle i s wi thdrawn i n the formof crystals whi le one thi rd ,
-

r emai ns behi nd li qui d lead The crystals wi ll then be abo ut half as ri ch

as .

i n Ag and the li qui d lead about twi ce as ri ch as the ori gi nal b ulli o n I n the
, , .

seco nd sy stemthe b ull i o n i n the k ettle i s di v i ded i nto seven ei gh ths cry st als -

and one ei gh th li qui d l ead and the Ag co ntent of the crystal s i s approxi m
-

, ately

one thi rd as m
-
uch and of the li qui d l ead approxi m
, ately thr ee ti m es as m uch ,

as that of the or i gi nal b ull i on The latter m ethod i s therefor e to be appli ed to

.
, ,

very lowgrade b ulli o n Stetefeldt tri ed to find a general mathem

-
l
. ati cal for m ula
whi ch would show the propor ti ons i n whi ch leads of di fferent contents i n Ag
sho uld be di vi d ed to at tai n w i th as fewcrystall izati o ns as po ssi ble a m
, ark et ,

lead Of a certai n tenor i n Ag and an enri ched lead In prac ti ce the two methods .

by thi rds and by ei gh ths have b eco m e sta ndards espec i ally the for m er A , .

vari ati on of the method by thi rds the one wi th i ntermedi ary crystals ai ms to 1
, ,

r educe the number of cry stalli z ati ons The contents of th e ket tle are di vi ded .

— tw o th i rds cry stals and one thi rd li q ui d lead

-
— and the crystal s tak en out
-
.

The li q ui d lead however und ergoes di rec tly a second cry stall iz ati o n so th at
, , ,

i nter m edi ary cry stal s and fi nal li q ui d lead wi ll resul t Thus the ori gi nal l ead i s .

di vi ded i nto 14 A n or m a l cry st a l s a ssa y i ng one half a s m u ch as th e or i g i n,a l -

l ead ; 16 i ntermedi ary crystals assayi ng the same as the ori gi nal lead ; and 16 ,

li qui d lead four ti mes as ri ch as the ori ginal lead The m

, ethod has ho w ever .
, ,

been abando ned where i t was tri ed as i t co mpli cated the process and as con , ,

si derable am ounts of sli gh tly enri ched leads had to be kep t on h and .

To carry out Patti nson s proc ess successft the lead b ull i o n m
’
ust not be
very i mp ure or run too h i gh i n Ag and a sufi ci ent amount must be used to ,

p e r m i t th e c ar ef ul r egu l a t i o n of t em p erature nec essary A ll the for e i gn m e .

tal s co ntai ned i n the lead i nterfer e wi th the cry stalliz ati o n and the effec tual
sep arati o n of th e li q ui d lead fro mth e cry stal s Ordi nary lead can be sufli ci ently .

p uri fied by poli ng and rem ovi ng the dross that collec ts on the surface ;
if Sn As and Sb are present to any extent the lead has to be sof tened ( 52 4 1 )
, , ,

at a bri gh t red h eat befor e th e cry stalli zati on can proc eed .

2 2 0 O ri gi nal Pattinson Process

.
— The plant consi sts of a set of from8 to .

1 5 sph eri cal k ettles ( wi th the m ethod by th i rds) bui l t closely togeth er i n a ,

row The kettles hold from6 to 1 5 tons of lead ; the smallest perm
. i ssi ble quan
ti ty i s 2 16 tons Each ket tle has a sep arate fireplace S0 constr uc ted that the
.
,

flame shall pass beneath and behi nd the kettl e thence i nto a flue enci rcli ng i t , ,

and final ly i nto th e ch im ney whi ch has a dam per to regulate the draf t The
, .

detai ls of the constr uc ti on are the sam e as wi th the d esil veri z i ng k et tle of -

Parkes process
The m ode of op erati on in outli ne wi th the met hod by thirds is as follows
In the central kettle the lead bulli o n i s m el ted dow n drossed and i f necessary , , ,

p o l ed T
. h e fi r e b e low i s t h en w i t hdr a w n a nd t r ansf e rr ed to a n ei ghbor i ng
kettle The cooli ng is promo ted by sp ri nkli ng water on the surface froma hose
. .

Cr usts adher i ng to the si des Of the k ettle are p ushed dow n i nto the lead wh ere ,

1
Berg H i a
le . mn Z . .
,
1 863 , xx rr, 64 , 69 , 77 .

1
Stetefeldt, I bi d .
, pp . 2 9 7, 3 8 1 .
472 ME TALLURGY OF LE AD

they melt again of one man who also sti r s the metal conti n
. Thi s i s the work ,

uously unti l th e sm oo th surface b ecomes rough wi th crystals H i s par tner now .

i nser ts at the ri mof the kettl e a long handl ed suspended Ski m mer that has been -

warm ed and works i t acro ss th e bo ttomof the k ettl e to the op posi te si de then
, ,

back to th e m i d dl e w here af ter j erking i t to r emove th e li qui d lead be di s

, , ,

charges th e dry crystals i nto the nei ghbori ng kettle generally the one to the ,
“
r i gh t ( down the The operati o n i s conti nued until tw o thi rds of -

th e contents of th e k et tl e have been r em oved i n the formof crysta ls The .

“
li q ui d lead i s th en ladl ed i nto th e k et tle on the lef t ( up the To the
kettle at the r i gh t bei ng two thi rds f ull of crystals one thi rd of lead of the
,
-

,
-

sam e tenor i s add ed and the k et tle at th e l ef t bei ng one th i r d f ull of l i q ui d l ead
, ,
-

i s filled wi th a corr espo nd i ng am o unt ( two th i r ds) of lead of i ts tenor T he -

.

kettles are h eated and the cooli ng crystalli z i ng and ladli ng carri ed on i n the
, , ,

sam e w ay as i n th e or i gi nal b ulli o n k ettl e Thi s beco m es agai n fi lled fromt he .

crystals of the k ettle on the lef t and the li qui d lead of that on the ri gh t Th us .

the oper ati ons are conti nued the lead of the k ettl es to the ri gh t decreasi ng i n ,

tenor ti ll th at of th e last one th e m ark et p ot assay s from to 0 5 oz Ag p er ,

-

, . .

ton; th at to th e lef t i ncr easi ng t i ll the m axi m umof 500 oz i s reach ed . .

Fromth e foregoi ng i t will be seen that before the whol e plant can be i n
worki ng order qui te a number of crystalli zati ons have to be carr ied on so as to ,

have on hand th e necessary amounts of lead of di fierent Ag contents req ui red

to fill the k et tles .

Patti nson s proc ess i n i ts ori g i nal formi s stil l i n use i n E ngland Frei berg
’
, ,

Saxony and p erhap s som

,
e o th er plac es As i t i s i m probable that i t wi ll be .

i ntrod uced anywh ere i n the Uni ted S tates thi s general o utli ne wi ll sufi ce , .

Full d etai ls are gi ven i n the works of Percy Kerl Schnabel Lo ui s Stii lzel
1 1 8 ‘
, ,
-

, ,

Rosw ag
1
Grii ner and especi ally the paper by Tei chm
6
, , ann
7
.

In order to red uc e the hard work necessary i n wi thdrawi ng the crystals and
ladl i ng out the lead as well as to i nsur e a more r egular crystalli zati on and bet ter
,

sep ar ati o n of crystal s and li q ui d l ead m achi nery w as i ntroduc ed i nto Patti nson s
’
,

process ; but the two m ai n m odificati ons of the ori gi nal process whi ch are i n ,

use to day are those by Luce and Rozan and by T r edinni ck

-

,
In bo th the , .

metal i s sti rred by steam and the li qui d lead drawn ofl leavi ng the crystal s , ,

i n th e k ettle
2 2 1 Luce and Rozan Process (SteamPatti nson Process) , General
.

.
“ -
.

Th e advantages of steamare that i t causes a regul ar cry stalli zati on and a ,

good separati on of the lead fromthe crystal s and that i t poles the lead whi ch , ,

“
1 Metallurgy of Lead, Murray London, 1 870, p 1 2 1 ,
. .

1 “Grundri ss der Metallh ti ttenkunde ” Feli x Lei si c 1 88 1

p p , , , ,
2 25

H andbook of Metallurgy Macm i llan London 1 90 5 Vol

”
1
, , , ,
. 1, p 6 2 5 . .

“
1 r w
Metallu gi e, V e eg Bruns ck
”
i wi 1 863
—1 886 p 1 1 2 2 , , ,
. .

1 “La desar entati on de lo b ”

g p , m Dunod , Pari s, 1 884 , pp . 2 1 1 and 2 6 7 .

1
Ann ,
. Mi n
p 3 79
. 1 868, XIII ,
.

1
Zt B erg H il lten S al W i Pr , 1 86 7, xv, 4 0
. . . . . . .

1
Luce and Rozan, Ann Mi n , 1 8 73, 111 , 1 60 . . .

Coo kson, E ng . Mi n . J .
,
1 881 , xxx , 2 39 .
474 M E TALL URC Y OF LE AD

to make th ei r way through passage 9 before passi ng downward th e narrow , ,

and ofl thro ugh flue r On ei ther si de of the large central fireplace is ( Fi gs

,
. .

47 1 an d 47 )2 a sm all er o n e wh i ch s erv es to h ea t d i sch a rg e,

spo ut s n
r b e for e -

, ,

usi ng th em E ach of th e di scharge spo uts A and B ( Fi g

. has a perforated -

,
.

cast i ron strai ni ng plate to keep back the crystal s when the li qui d lead i s bei ng
- -

run 03 . These are held i n place by wro ugh t i ron arm s b and cast i ro n -

, ,
-

frame c ( Fi gs 4 74 and
,
. whi ch i s fastened by key bo lts to bafll e plate d -

,
.

The spo uts are closed by a sli de valve ( Fi gs 4 78 4 79 To the flange of -

.
, ,

th e spo ut ( Fi g 4 76) i s fastened wi th co untersunk scr ews and a red l ead cem
. ent -

a plate ( Fi g 4 77) of the sam

. e form w i th one face planed sm oo th having fo ur , ,

op eni ngs to correspond to those of the flange; i e the central lead discharge and . .
,
-

the thr ee hol es near the ro unded corner s Thro ugh th ese bol ts m and rn
’
.
, ,

are passed m servi ng as a pi vo t for lev er o and mto ti gh ten gui de n

’
,
To , , ,
.

the l ev er i s fastened plate p also h avi ng one planed fac e ,

In Fi g 4 78 i s
, . .

shown th e po si ti o n of the lever wh en th e di scharge i s clo sed In order to .

open i t the nuts of screw bol ts m are loosened and the lever pushed i nto
,
-

, , ,

the second posi ti on shown by the do t ted line , s The lead fromthe crystalli zer .

passes thro ugh the two lead spo uts i nto two tap eri ng molds ( Fi gs 4 70 and .

each of whi ch ho lds abo ut 661 0 lb of lead The steami nlet consi sts of th e . .
-

followi ng parts ( Fi g On th e flat bo ttomof the crystallizer are fo ur

.

bosses f i nto whi ch fit screws g On the collar of these i s plac ed and keyed
m
.
, , ,

the cast i ron circular ba e pla te d wi th i ts sm

-
all openi ng c i n the center
-
It , , , ,
.

serves to di st ri b ute th e steamev enly and to m ak e i t ri se r egularly i n th e p ot ,

.

Fromi t i s suspended by an eye bol t i wi th hexago nal eye nozzle h i nto whi ch -

, , , , ,

i s scr ewed steampi pe e Through i t passes rod k m -

,
. oved to and fro at one , ,

end by the thread and cross bar; the o th er end whi ch i s co ni cal fits i nto the -

, ,

coni cal valve seat of nozzle h and closes or opens the steamoutlet The
-

, ,
-
.

steamenter i ng at S ( Fi g 4 74 ) passes thro ugh the sm all annular space between

.

p i p e an d r od a nd o u t a,t h wh e n th e v a lv e i s op en ,
.

The m ethod of worki ng i s the one by thi rds The m ode of conduc ti ng the .

process i s si mple Suppose the process to be goi ng on at the stage when th e

.

li q ui d lead has been drai ned 05 fromthe crystalli z er ; the valves have been
ag ai n c lo sed and the crystals li quefied One pan wi ll be full of li q ui d lead of .

the sam e tenor i n Ag as the m el ted crystal s to be di sch arged i nto the cry s

tall i zi ng p ot whi le the o th er w

,
i ll contai n tw o cakes of lead that are bei ng

melted down They will have the same Ag contents as the crystals remai n
.

i ng i n the crystalli zer af ter the operati on to be d escri bed has taken plac e .

The m el ti ng do w n of tw o cak es ta k es abo ut 6 hr .

The lead fro mthe p an i s run out by i nser ti ng tw o hook s fastened to the ,

chain susp ended fro m the pulley of the crane i nto the ears of the p an and , ,

rai si ng i t slowly Af ter the lead has been discharged i nto the crystalli zer the
.

doors of the hood are closed and steami ntroduced for 2 m i n and sh ut ofl agai n ; .

when the p ulverulent dross whi ch has collec ted on the surface i s removed N ow .

the cry stallizati o n proper b egi ns The fire b elow the cry stalliz er i s wi thdrawn .

and di vi ded b etween the tw o sm all fireplac es on ei th er si de fro m whi ch th e lead ,

 DE S ILVE RI ZA TI ON OF LE AD B ULLI ON 475

s pouts are warm ed Steami s tur ned on and a sm

. all jet of water i s allowed to ,

play at shor t i ntervals upon the surface of the lead E very ti m e the water i s .

let on th ere are sm all explosi ons and as soo n as th ey beco m e too vi ol ent the
,

water i s shut ofl agai n whi le the steamenters conti nuo usly The steamhas
, .

45 lb pr e
. ss u r e to th e s q ua r e i nch a n d ca r e mu st b e tak e n t o h a v e i t d r
,y A bo u t .

15 m in af ter i ntrod uci ng the steam the lead that has b een splashed up on
.
,

the upper edge Of the p ot or on the hood has to be r em , oved The steami s , .

shut ofi the doors i n the hoo d are opened one after the o th er and the soli d ified
, ,

lead crusts broken OH wi th a chi sel poi nted bar and p ushed back i nto th e lead
- -

, .

Thi s sh ut ti ng ofl of steamto r em ove the lead i s repeated at least twi ce While .

the crystall i zati on i s going on the tw o cak es of lead r equi r ed to fill agai n the
,

melti ng p an j ust empti ed into the crystalli zer are hoi sted frombelow wi th the
-

, ,

crane and depo si ted one on top Of the o ther i n the p an The crystalli zati on i s
,
.

fi ni shed when the nor m al am ount of steamcan no longer overco me the resi s
tance Ofi ered by the crystals The r esul t i s th at the bo ili ng ceases and the sur
.
,

fac e of the cry stalli ne mass of lead shows only a slow wave lik e mo ti on Two ,
-
.

th i rds of the ori gi nal lea d have nowbeen conver ted i nto cry stals th e lead havi ng ,

assum ed a m ush y consi stency Water and steamare shut ofl the sli de valves
’
.
,
-

are Op ened and th e li q ui d lead i s di scharged i nto th e m

, olds whi ch takes fro m ,

8 to 1 0 m in In these have pr evi ously b een placed i ro n books by whi ch the

.
,

cakes Of lead when cold m , ay be li f ted out The whole process of crystalli za
,
.

ti o n lasts about 1 hr Whi le the lead i s runni ng ofl th e fire fromthe two small
.
,

fi rep l ac es i s returned to the grate below the cry stalliz er and urged i n p rep ara ,

ti on for the nex t op erati on .

The m el ti ng and o th er work requi re 3 hr so that one op er ati o n last s 4 hr .

, .

E l even cry stalli za ti o ns are nec essary to ob tai n m ark et lead fromli quated

l ead bull i on averagi ng oz Ag to the ton Table 1 1 0 sho w s the average

. .

assay value i n o unc es p er ton of th e di fl erent leads prod uc ed dur i ng a who le

-

year s work ’
.

Si x charges are run i n 2 4 hr ; tw o m en worki ng as par tner s at tend to the .

crystalli zati on all the handli ng of the lead bei ng done by the crane man and hi s
,
-

helper The pro duc ts of the process are ri ch lead desi lveri z ed lead dross and
.
, , ,

flue d ust
-
The ri ch lead i s c up elled the desi lveri zed lead i s r efined i n a rev er
.
,

beratory f urnace and m olded i nto m ark et lead th e dro ss and flue d ust are work ed ,
-

wi th si mi lar pro duc ts fro mo ther parts of the works The outp ut of m etal i s .

shown by Table 1 1 1

The m ateri al co nsum ed for d esi l veri zi ng 1 00 to ns of l ead b ulli o n exc lud i ng

the refini ng of the lead i s : Ch arcoal 2 5 b ush els ; b i tum ,

i no us coal to ns , ,

for m l i g d d i lv r i z i ng) b i m i o s co al o s ( for rai si ng st eam )

( e t n a n e s e t u n u t n ,
.

Balli ng gi ves the li fe of a m

1
el ti ng p an as 4 0 d ay s of a cry stalli z er as 1 2 0 ,

d ays whi ch seems very low

,
.

I t has already b een stated that b efor e the process can be carri ed on nor m all y ,

a num ber of preli m i nary cry stalli zati ons have to take place to furni sh the nec
essary i nter m edi ary prod uc ts On account of the possi b ili ty that the process
.

“ ”
1
M etallhuttenk unde , Sp ri nger, Berli n, 1 885, p . 2 95 .
476 ME TALLURG Y OF LE AD

wi ll be co m bi ned wi th the Parkes process in thi s country because of the behavi or

of bi smuth ( see Tred i nni ck process ful l detai ls of the manner of star t ,

i ng th e pl ant at Pi i bramare g i v en al th o ugh th ey i nvolv e m uch rep et i ti o n

'

, .

The o utli ne repr esents 1 1 operati ons each req ui ri ng one m ore charge than the ,

one precedi ng b efor e m ark et lead can be prod uc ed and gi v es the 1 2 grad es of
, ,

argenti fero us lead I X I I the v al ues of whi ch are gi ven i n Table 1 1 2

—
, The , .

used at Pi i bramhave b een r etai ned as changi ng theminto po unds

“q ui ” ‘
ntals ,

wo uld have depri ved the scheme co m pli cated as i t i s of the necessary clearness , , .

One q ui ntal i s equal to 1 00 ki logram s and th ese eq ual lb avoi rdupoi s . .

The star t i s of co ur se m ad e wi th blast furnac e l ead b ulli o n B F X I assay ,

. .
, ,

i ng oz p er ton and 1 80 q ui ntals i s the am

. ount gi ven b elow i n Operati on
,

1,
whi ch upon crystalli z ati on wo uld f urni sh 60 qui ntals li qui d lead L L X I I , . .
, ,

wi th oz Ag p er ton and 1 2 0 q ui ntals cry stal li z ed lead C L X wi th

.
,
. .
, ,

oz Ag p er t on . As the separati o n accordi ng to thi rds i s nev er acc urate

.
,

these figures are not ac tually Ob tai ned and as f ur ther i n m el ti ng poli ng et c , , , ,
.
,

a consi der abl e am o unt of dro ss i s formed the star t i s made wi th 1 90 qui ntals ,

i nstead of wi th 1 80 qui ntals and i n the operati ons 1 30 qui ntals are charged ,

stead of 1 2 0 E ven wi th these larger am. o unts the wei gh t of the m ark et lea d ,

ob tai ned ranges o nl y fro m1 05 to 1 1 2 qui ntals .

TAB LE 1 1 0 — . AO—AS S AYS or LE ADS rN LU CE ROZ AN PROCES S , Pk

-
An , BOHE mA
Ounces Ag per T on

Kettle N o .

Market lead

T AB LE 11 1 .
— DrsTRrBU1 1 0N or PB AND AG rN PRODU CTS

O O O O O O O O O O O O O O O O O

O P E RA T I O N I

Cha rge 1 . Blast furnace

lead b ulli on 1 80 B F X I ; gi ves 60 L L X I I ,
. . .
, .
, ,

whi ch go to the cupell i ng furnace ( cup el ) and 1 2 0 C L X wh i ch are li q uefied . .

, ,

i n the crystallizer , drawn ofl into the m olds and stacked on the floor (floor ) , .
4 78 ME TALLURGY OF LE AD
V
TAB LE 1 12 .
— OPE RAT1 0N or LU CE RO ZAN PRO CE S S , FRIE R A H ,
-
B OH E urA — ( Coruznued)
.

Charge Gi ves crystalli zed lead

Source Desti nati on

x Floor

60 viii Floo r

v n Floor

60 vi Floor Floor

xn Cup el 1 20

xi Floor

x Floor

ix Floor

60 vi ii Floor

60 vn Floor

60 vi Floor

v Fl oor

xu Cup el 1 20

xi Floo r

ix Floor

vii i Floor

vu Floor

vi Floor

v Floo r
480 M E TALLURGY OF LE AD

OPE RATI ON II

Charge gi ves 60 L L X II to cupel and 1 2 0 C L X

1 . 1 80 B F. .
, XI ; . .
, , , . .
, ,

remai ni ng i n the crystall i z i ng k et tle ; th ere are add ed fromthe mel ti ng po ts

60 C L X fro mOperati o n I charge 1 to m

. .
, , ak e up , ,

Charge 2 1 80 X ; gi v es 60 L L X I to floor and 1 2 0 C L 1X to floor

.
,
. .
, , , . .
, ,
.

OPE RA TI ON III

Ch arge 1 . 1 20 B F . .
, X I, and fromOp erati on I I charge 2 gi ves
60, X I , , ,

60 L L , X II , to cupel ,
. . and 1 2 0 C L, . . X ; add r emai ni ng 60 C L X fromOp era . .
, ,

ti o n I , charge 1 to m ak e up ,
.

Charge 2 1 80 X ; gi ves 60 L L .
,
. .
, X I , to
floor and 1 2 0 C L IX ; add 60 , . .
,

C . L IX fromOp erati on I I charge 2

.
, , , , to make up .

Charge 3 1 80 IX gi ves 60 L L .
,
. .
,
X to floor and 1 2 0 C L VI I I to floor
, . .
, , ,

precedi ng table gi ves system

The a ti cally arr anged all the pr eli m inary steps
necessary to arr i ve at th e po i nt wher e th e fir st m arket lead i s prod uced .

I t th us r eq ui r es 66 cry stalli zati ons to ob tai n th e i nterm edi ary prod uc ts

necessary for nor m al work One half of th e cry stalli z ed lead fromOper ati on .
-

X charge 1 0 r em
,
ai ns over to be work ed ofl sub seq uently
,
.

In com p ar i ng th e proc e s se s of L u c e R o z an a n d Pa tti n s o n C o o k so n 1

co m e s t o -

the concl usi o n that the form er i s to be pr eferr ed by far as th e sof teni ng of th e ,

lead i s not so i mp erati ve the co st of labor only 2 0 p er cent and tha t of fuel , .
,

0
4 p er c ent of th e co st by P a tti.ns o
, n s proc ess ; an d la s tly i t prod uc es o n l y ’
, ,

3
3 p er c ent of th e am o un t of d ro.sse s ob ta i ne d by P a t t i n s o n T h e dr a wb a ck .

of the greater ori ginal cost and the co ntinued expense of repair and renewal , ,

is m ore than made up by the advantages .

2 2 3 Luce and Rozan Process , Eureka, New

.
t — In 1 874 the Ri ch m ond
Consoli dated M ini ng Co i ntro duced thi s process at E ureka ; work conti nued 1
.

unti l The capaci ty of the first crystalliz er w as 2 2 to ns ; i t w as i n

creased i n 1 878 to 50 to ns 1
The lead b ulli on av eragi ng 1 00 oz Ag and 1 5 oz .
,
. . .

Au p er ton w as de s i lveri zed by 4 m ,

en i n 1 1 operati ons of 2 0 m i n each to .

0 5 oz
. at a co st of $ 1 3 00 p er ton
. Accordi ng to A Wetz stei n i t w 1
as found
. . .
,

that enlargi ng the cry stalli z er from a capaci ty of 2 2 to 50 tons perm i tted
maki ng 1 0 operati ons i n 2 4 hr i nstead of the usual 6 or 8 as the separati on .
,

of cry sta ls fromli q ui d lead was qui ck er and better Cur ti s gi ves the followi ng 7
.

values in o unc es Ag p er ton for the produc ts : 460 ( ri ch lead) 1 05 1 00 75

, , , , , ,

1
E ng . Mi n . J .
,
1 8 79 , xx vrr, 2 58 .

1
Curti s,
“Silver lead -
D ep osi ts of E ureka, N ev .
,
monograph U . S Geol Survey,
. . 1 88 4,

“ McGrawHill Book Co NewYork ,

1
Ingalls , W R , Lead and Zi nc in the Uni ted States,
. .
-
.
,

1 90 8, 77 .

1
Letter of R K Morri son, Sup t , March 7, 1 90 1 . . . .

1
Let ter of A Tredi nni ck , May 1 5, 1 903 . .

1 “The I
p roved Pat ti nson Proce m
ss ,
”
Butte,
M ont .
,
n d ;
. . Mi n . I nd .
,
1 0 2
9 , 111 , 4 51
1
Loc . ci t.
 DE SI LVE RI ZA TI ON OF LE AD B ULLI ON 48 1

5 ,
0 0
3 , 1 8 , 9 , 5, 2 .
5, 5 ( mark et l ead ); T r edi nni ck 1
sta tes that the Ag -
content
of the mark et lead never exceeded 0 5 oz . . Ag p er ton .

1—
2 24 . Tredi nni ck Process, General patented by Steph en . Thi s process,
Tredi nni ck i s i n par t a com bi nati on of the ori gi nal Patti nson and Luce Rozan
,
-

processes I t has a cry stalli zer for each grade of lead as has the Patti nson ;
.

i t stirs th e l ead wi th steamand drai ns 03 the li qui d lead as does the Luce
Rozan The i nnovati on i s that each cry stalli zer i s m
. o unted on a hydrauli c
platformso that i t can be rai sed when i t i s to deli ver lead and lowered wh en i t ,

recei ves lead A battery of usually 1 1 cyli ndri cal cast i ron vessels is bui lt in
.
-

a row wh i ch has at one end a k ettl e for m ark et lead and at the o ther one for ,

enr i ch ed lead whi ch i s to be c upelled or elec trolyzed .

Th e process has not been used so far for desi lveri zi ng l ead bulli on but w as ,

p ut i nt o op er at i o n a t O m a h a N ev for th e r ecov e ry of B i fro m l ead wh i ch ha d ,

.
,

been desi lveri zed by the Parkes process I t di d thi s work sati sfac tor ily but .
,

has been abandoned as there w as not eno ugh Bi b eari ng l ead i n the m
, ark et to -

warrant r unni ng the plant At present the small amount of bi smuthi c lead .
,

i n the m ark et i s m i xed wi th lead bulli on m ade fromBi bear i ng leady m ateri als -

and tr eated by th e B et ts proc ess

There i s no q uesti on that the Tredi nni ck process w ill gi ve excellent resul ts
wi th si lver as thi s m etal i s m, or e sati sfac tori ly concentrated in an enri ched lead
than i s bi sm uth Of co urse i t wi ll not m .ake corrod i ng lead fromCu bearing ,
-

lead bulli on as Pat ti nsoni zi ng does not eli m

, i nate the Cu to the req ui red de
gr ee Thi s i s shown i n Table 1 1 3 gi ven by N ewnam who studi ed thi s feature
.
1
, .

TAB LE 113 — DE COPPE R1zATrO N

. or LE AD BY PATTrNSO e rN O

Ket tle

Enri ched lead

I mpove i r shed lead

1
Loc . ci t .

1
U S Patent, N o 66 2 836, Nov
. . . . 2 7, 1 900 .

Austi n, Mi n . S c Press, . 1 90 7, x crv, 89 .

N ewna m Bull , . A I . . M . E .
, M ay , 1 91 7, 749 .

Wetzstei n, Mi n . IM .
,
1 90 8, x vn, 605 .

1
Loc . ci t.
31
482 ME TALLURG Y OF L E AD

The followi ng di scussi on based on the above paper by N ewnamq uo ted , ,

deals wi th the Tred i nni ck process for the treatment of lead wi th p erc e n t .

Bi desi lveri zed by the Parke

, s process wi th the obj ec t of ob tai ni ng lead w i th ,

1 p er cent Bi to be elec trolyzed by the Bet ts proc ess and corrodi ng lead w
. i th
p er ce n t B i t o go t o m ark. et .

The freezi ng po i nt c urve of the alloy seri es Pb Bi Fi g 1 3 show

- — s th at Bi , .
, ,

melti ng at 2 68 C and Pb melting at 3 2 1 5 C forman eutec ti c wi th 44 per

°
. . .
°
.
,
°
cent Pb freezi ng at 1 2 5 C ; and soli d soluti ons up to 1 0 p er cent Pb i n Bi
.
, . .

and 1 0 p er cent Bi i n P b If w e h av e m
. ol ten lead wi th a sm all am o unt say
.
,

3p er ce n t B i an d cool. to 3 2 1 5 C th er e
, w ill f a ll o ut of sol uti o n a t fi rs t l ea d .
°
.

and th en w i th falli ng tem

,
perature lead wi th i ncreasi ng amo unts of Bi un ti l this , ,

reache s i ts m axi m um of 1 0 p er cent j ust above the eutecti c li ne at 1 2 5 C

°
. .

The exi stenc e of thi s soli d soluti on of Bi i n Pb gi ve s the r eason for the difi cul ty

of ob tai ni ng m arket lead wi th le s s th an p e r c en t B i . .

In crystalli zi ng Ag beari ng lead wi th the m ethod by thi rds the crystals are
-

abo ut half or 0 5 ti m es as ri ch and the li q ui d lead t wi ce or 2 ti m

. es as ri ch i n ,

Ag as the ori gi nal lead bulli on Wi th bi sm uth the li qui d lead co ntai ns about .
,

ti m es the perc entage of Bi of the l ead i n the ch argi ng k et tl e w hi ch rep ,

resents approxi mately a 40 per cent enri chment ; the li qui d lead contai ns about -
.

ti m es the Bi content of the ori gi nal lead whi ch i s eq ual ap proxi m

-
ately

poveri shm
,

to a 2 0 per cent i m -
ent These fac ts are shown i n Table 1 1 4
. . .

TABLE 1 1 4 — CHA N 0E S 1N Br AND . AO -

CO NTE NT B Y PATTrN S Oe rN o

Kettl e NO 1 2 3 4 s 6 7 8 9 10 11

Bi p er cent .

A3 oz p er ton
.
14 14 1 2 4 7 12 20 35 60 1 00 1 80 300

Th e mi si ng
s 40 formati on of soli d sol uti ons i s the cause
p er cent .
, due to the ,

of the tendency of the Bi content s of the ket tles between the corrodi ng and -

the chargi ng ends to i ncrease steadi ly i n th ei r tenors of Bi , Thi s tendency has .

been term ed the crawl .

In a seri es of 1 1 crystalli zi ng ket tl es each havi ng a worki ng cap aci ty of 63 ,

t ons lead N o 1 repr esents the Bi poor and NO 1 1 the Bi ri ch end ; No

‘
- -
. . .
,

8 i s charged wi th 63 tons of lead wi t h p er c ent Bi C ry st all i zi ng No 8 . . .

wil l furni sh
NO 7 w i th 2 1 tons li q ui d carryi ng
.
p er ce nt B i . .

Th e kettles stand thus :

Per cent B 1 .

Nowcrystalli ze N O 7, w hi ch will f urni sh .

No 8 w i th 2 1 tons li qui d carryi ng

.
p er c e n t Bi . .

No 6 w i th 4 2 tons crystals carryi ng

.
p er c ent B i . .

Charge N O 8 w i th 4 2 t ons of lead at

.
p er ce nt Bi ; . r
ave age contents

No 8. wi ll t hen be 63 tons carryi ng p er cent . Bi .

Crystalli ze N o 8 w hi ch wi ll f urni sh .

NO 9 w. i t h 2 1 tons li q ui d carryi ng p er cent . Bi .

NO 7 w. i t h 4 2 tons crystals carryi ng p er cent . Bi .

484 ME TALLURCY OF LE AD

The kettles wi ll stand

readily be seen that thi s is an accumulative crawl and while i t is aggra

It can
”

vated each ti me No 9 i s brought i nto play and in like manner more so when N O 1 0
. .

and N o 1 1 are draw

. n upon yet i t w ould exi st were there no kettles above N o 8

Furth erm
. .
,
“
ore th e p ercentage rate of
, crawl of No 2 or any other kettle wi ll be the
”
.

same as that of NO .

r wl or enri chm
Thi s c a , ent i n Bi content over that whi ch i s norm
-
al for a

ket tle can be corrected ei ther by tappi ng a kettle whi ch i s overgrade i nto the
,

kettl e of next hi gher grad e or by i ncreasi ng the num ,

ber of crystallizati ons A .

com bi nati on of the two methods i s efi ected by the so call ed j um “ ”

ps i n whi ch-

the 2 1 tons of m el ted crystals fromkettl e N o 1 are tapped i nto k et tl e N o 2

. .

holdi ng 4 2 tons of crystals and then worki ng strai ght up the li ne wi tho ut
,

tappi ng back any cry stals Th us the crystals recei ve an extra operati on and
.
,

one t hi rd li q ui d l ead i s p ush ed u the li ne by ucc e i v tage T abl es 1 1 5

p s ss e s s
-
.

and 1 1 6 Show t he i ncrease i n Bi content w i th o ut and wi th j um

-
pi ng (J ) i n a
1 0 k ettl e pl ant
-
.

TAB LE — I N CRE AS E rN Br CO NTE NT WrrH OUT

11 5
.
-

J 01 1 2 1 17 0
 DE S ILVE RI ZA TI ON OF LEAD B ULLI ON 485

T AB LE — INCREAS E Br CO NTE NT W 11 H
1 16. rN -

JUMPl N O

2 2 5 Plant
.
— The plant under consi derati on was constructed to t reat dai ly
about 2 00 tons lead w i th the m ethod by thi rds and to prod uce fromlead wi t h ,

0 33 p er c ent Bi a corrodi ng lead w

. .
,
i th 5p er cen t B i and a n e nri ch ed l ead .
,

wi th 1 p er cent Bi to be elec t rolyzed Thi s requi red 1 1 crystalli zers each hold
. .
,

i ng 63 tons of lead It consi sted of one 1 80 ton storage reverberatory f urnac e

.
-

for the lead to be treated ; 1 1 crystalli zers ( Fi gs 4 83 wi th a worki ng .

capaci ty of 63 tons each placed i n a li ne at 1 2 ft centers ; one 1 50 ton moldi ng

,
-
.
-

furnace for corrodi ng lead ; one 4 2 ton kettle for moldi ng anodes ; one 1 50 -

ton reverberatory f urnace for the red uc ti on of drosses ; one 1 8 ton l adl e for charg -

i ng the crystalli zers usuall y No 8 ; one oblong sp out kettle fill ed wi th hot
,
.
,

l ead for heati ng the tappi ng spouts whi ch are kept i n i t unti l needed ; one
,
-

2 5 ton elec tri c traveli ng cr ane for handli ng the 1 8 ton l adl e for replaci ng de
- -

fecti ve k ettl es (done i n 2 0 and for handli ng i n general .

2 2 6 Crystalli zer
.
— D etai ls of th e crystalli zer are shown in Fi gs 4 83 4 85
.
—
.
,

whi ch represent an elevati on Of a k ettle stand wi th connec ti ons and d etai ls of -

th e k et tle A k et tle 7 ft 1 i n i n diam

. eter and 6 ft 3 i n deep i s surro und ed
,
. . . .
,

and carri ed by a co m b ustion chamb er i nclosed i n a bri ck lined sh eet steel - -

casing Thi s i s erec ted on an I beambase wi th sup por t chai rs and i s rai sed and
.
- -

lo wered by a hydrauli c ram 2 6 i n in di am eter whi ch has a strok e of 7 ft l and

,
.
, ,

works under a hydrauli c pressure of 500 lb p er sq i n S tea mi s admi tted . . .

on th e si d e clo se to th e bo t to m thro ugh a valve whi ch d eli v ers at th e c enter

, ,

under a h eavy perforated p la te 4 5 i n i n diam eter I t enters the valve thro ugh a
,
. .

tel escope p i pe connec ti on at a pressure of 1 1 0 lb p er sq i n

-
The . . .
486 M E TALLURGY OF LE AD

cover of th e k et tle i s a sh eet metal hood wi th four worki ng doors i n th e si des and
- -

a 13 -
ln . O p eni ng i n th e top co nn c t d by a t l e cop
e e p i p e w
e i th a h eet mt
eal fi
s n s -
e e.

Th e flue i s provi ded wi th running at 300

an 8 ft-
whi ch . exhaust fan,
removes waste steamand p o wdery oxi des of lead Fo ur inches above the top .

of the cover i s a i n c i rcular water p i p e 2 4 i n i n d i am

-
. eter wh i ch has ei gh t -

,
.
,

holes on the lower S i d e for the deli very Of coo li ng water i nto the ket tle

Water Val ve

SO Dla

FI G .
4 83.
— T redi nni ck N ewna -
mcrystalliz er, eleva ti on .

thro ugh funnel shap ed cup s The water connec ti on i s made by a 14 in hose
-
.
- -
.
,

9 f t lo
. ng B o t h w a t er a
.nd steam are co nt ro ll ed fro mth e seco nd or k et tl e , ,

flo or A k ettle i s fi red wi th O i l thro ugh three ato mi z er b urners Op era ted w i th

.

an oil p r essure O f 4 0 and an ai r p ressure of 2 4 oz p er sq i n

-

, Co nnec ti on w
-
i th . . .

the oi l tank i s m ad e by a 14 i h
-
metalli c ho se and wi th the ai r recei ver by
-
.
,
-

a 2 i n fl exi ble suc ti o n ho se

-
. The w aste gases are wi thdrawn thro ugh three
.
4 88 ME TALLURGY OF LEAD
No . 1 melted crystals ready to crystalli ze Kettles N02
kettle is full ( 63 tons) of . .

2 to 0 i nclu i ve are each t w

1 o thi rd full ( 4
s tons) of m elted c yst als and N o 1 r k ett le
-
s 2 r , .

i s em t
p y T h e p erc
.entag e o f b i smuth i n ea ch k ett le i s i ndi ca ted belowthe ket tles

E D O OO OE E E O

OOO fl
U P

Fro .
4 86
— w msystemfor Tredinni ck p rocess
N e na .

and rep resents the ap p roxi mate grade at whi ch t hey should be mai ntai ned . All
cha rges to be p laced i n N o . 8 k ettl e .

The p lant stands as follows:

Kettle NO 8 9 10 11
“

ée e e e ee o
.

E ee e I
Per cent . 04 10

No . 1 k et tle i s nowcrystalli zed the k et tl e elevated and 21 tons of li q ui d are tapp ed

i nto N 0 . 2 kettle, maki ng i t a full k et tle
. The 4 2 tons of crystals i n No . 1 kettle are
 DE SILVE RI ZA TI ON OF LE AD B ULL I ON 489

mlt
e ed and 2 1 tons are tapp ed to the corrodi ng lead -
mldi ng fu nace thus completi ng
o r ,

op erat i on No . 1 .

The p lant stands as follows

“
Tfi o e o e e e eeeé é I

NO . 2 ket tle bei ng f ul l, i t i s nowcrystallized and 2 1 tons of li q ui d tap p ed i nto No 3 .

k ettle, filli ng i t As soon as t he 4 2 tons of crystals i n N o 2 are elted, the kettle i s

. . m
v
agai n ele at ed and cont ents t ap p ed to No . 1 ket tle, filli ng the lat ter and co mpleti ng
r
op e ati on No . 2 .

The p lant st ands as follows

Kettle NO 3 9 10 11

n oo eéee ee eoo
. 5

a I
Operati on N 0 . 1

Kettles Nos wbei ng full i t is evi dent that these t wo kettles m

. 1 and 3 no ay be ,

op erated at the sam e ti m e req ui ri ng t wo crews As th e first crewp rogresses up the

, .

str i ng t he second creww

, ould foll owbehi nd and as closely up as m elti ng of t he crystals

would p ermi t In actual p racti ce usually two or three kettles i ntervene between the
.
,

tw o crew s In order to avoi d confusi on i n the cycle di agramthe w

. ork of the tw o crew s ,

i s show n i n alt ernati ng li nes ; thus t he first creww orks out the string m ark ed Seri es A
, ,

LE G E N D FO R F I G .
4 86 .

E mpty ket tle

K ettle contai ni ng 21 tons mlt e ed crystals.

K ettle contai ni ng 42 tons melt ed crystals .

K ettl e contai ni ng 21 tons enri ched li qui d .

K ettl e contai ni ng 42 tons enri ched li qui d .

Full ket tle md a e up of 42 tons of mlt e ed crystals and 21

of enri ched li qui d .

0 Ket tle contai ni ng charge of 4 2 tons .

Showing di recti on of the movement of melted crystals .

—0> Showing di recti on of the movement of the enri ched li qui d .

Corrodi ng l ead mldi ng furnace

o .

A node 01 enri ched lead -

moldi ng furnace .
490 ME TALLURGY ’
OF LEAD

after whi ch the second r crewworks sta t ed in actualout the Se i es B, alt hough , as ,

p ract i ce t h ey f o ll o w as c losely behi nd o ne an oth e r as p la n t con di t i o ns w ill p erm i t .

Returni ng to the last di agram the first crew will succes si vely crystal li ze the ,

ket tles 3 to 1 0 i nclusi ve and t he operati on on N o 1 0 wi ll p lace 2 1 t ons of li qui d i nto

, .

the em t
p y k et tl e N o 1 1 I n each case th.e m elt ed cry. st a ls are t app ed to w ard t he

corrodi ng end .

The p lant w i ll stand as follow s

Kettl e N o . 5 6 7 8 10 ll
”
El I sa - 1

Operati on No. 1 2 8 4 5 6 7 9 10

The first c e r whas thus made 1 0 op e ati ons on r the long st ri ng, Seri es A . The
second crewnowbegi ns on No 1 kettle and i n lik e m anner successi vely op erat e s the
.
, ,

kettles N 00 r to 9 i nclusi ve and the op erati on on No 9 w

. i ll p lace 2 1 tons of li q ui d i nto
,

the e mp ty kettle No . 10 .

The p lant wi ll stand as follows

Kettle No. 1 0 9 10 11

Al l

The crewhas thus made ni ne op erati ons on the long st ri ng Seri es B and
second , ,

t he first crewnowret urns to N o r kettle to w ork out i ts second st ri ng or Ser ie s C .

, .

Ow ing to t he necessi ty of correcti ng the grade of the ket tles as p revi ously exp lai ned , ,

a vari ati on of t he p rocedure nowt akes p lace i n Seri e

s C Duri ng t his seri es none of .

the m elted crystals are t ap p ed tow ard t he corrodi ng end but are left i n th ei r o ri gi nal

kettles wi th the excep ti on of the crystals i n NO 1 2 1 tons of whi ch i nstead of bei ng .

, ,

tap p ed to the corrodi ng furnace are tap p ed i nto No 2 kettle and the p lant st ands as ,
.
,

follows
9 10 11

I EDG Q Q G Q Q O O O O I m c s -

O p erati on N 0 . 11 12 13 14 15 16 17 18

The second wreturni ng to the corrodi ng end to work out i ts Short stri ng Seri es
cre ,

D i s obli ged to p ass over kettle N o 1 and begi n operati ons on the full k ettl e No 2
,
.
, .
,

thus p roceedi ng st rai ght up the li ne w i th t he op erati on on No 8 k et tle p laci ng a second .

.

tap of 2 1 tons of li qui d i n N o 9 ket tle As all crystals on thi s seri es are tap p ed back .

i ll leave t he charge k et tle No 8 em

.

as usual and as thi s w

,
t
p y i t i s i n o rder to gi ve i t a .
,

4 2 t-
on ch arge .

The p lant st ands as follow s

Kettle No . 7 8 9 10 ll

1 11 . I 'd - D

O perati on N o
3 :
1 1 I
2
.

No 8 . havi ng been charged will nowbe run out by the first crewand
, t he Seri es E ,

it wi ll be observed th at the operati on of N O 8 w ill fill kettl e No 9 whi ch must then . .

,
492 ME TALLURGY OF L E AD

should t ese taps be h m

ade i n group s of one, three, or fou , an enti r rely difi erent cycl e

w r
ould esult , necessi t ati ng a sep arate di ag a for each i nst ance r m .

Duri ng the p eri od ,

the i ngoi ng and outgoi ng lead was as follows

Corrodi ng lead, ei ght tap s of 2 1 tons each

Anode lead, two tap s of 2 1 tons each

Charge lead, five charges of 4 2 tons each

Di vi di ng these tonnages by the total nu mber of op erati ons ,

1 38, the tons o f lea d
charged and p roduced may be exp ressed as follows : Tons p er op erati on— ch arge

r
co rodi ng anode

2 28 . Detai ls of detai ls of an op erati on are as follow

— r
An O pe ati on The . s

A full ket tle ( 63 tons) , ski m m

ed cl ean and ready to crystalli ze, should have a

t em p erat ure not u ch ab ov e t h e m e lti n gp o i n t o f le a d, bmu t t he bri ck wo rk s ur

-
rou n di n g
t he kettle should be hot enough to p revent a crust f ro for i ng on the i nsi de of th e m m
ket tle Correct t em
.
p erat ure is an i p o rt an t f ac t or , a s le ad t oo h om
t gr eatl yp r o lo n g s

m
t he ti e of crystalli zi ng and p roduces an excessi ve a ount of dross
, I n p racti ce, t h e m .

l ead i s tested by thrusti ng a bro o handle m i nto the molten met al ; i f the lead freezes t o

m
t he handle the te p erature i s lowenough to p roceed wi th the op erati on If the lead .

does not f reeze to the handle, the ket tle ust be cooled w i th water, causi ng crust s t o m
formwhi ch are p ushed unde the surface r wi th a pole until the p rop er temp erature i s
secured . As this also consu m es ti m e, it is necessary to keep a sharp w atch on th e

te mp erat ure .

The kettle bei ng i n t he p rop er condi ti on, the op erator Op ens t he stea mvalve slo wly
until the surface of the lead i s vi olently agi tated .
(I n order to p revent slop p i ng the ,

ket tles are filled to wi thi n 1 5 i n of the top only ) . . W ater i s nowcauti ously introduced
t hro ugh the ei ght w at er cup s in the cover The op erator regulat es the ad i ssi on of . m
stea m and w ater so t hat a axi u a ount of w m mm m
at er i s i nt roduced wi thout causi ng
exp losi ons, th e formati on of chunks , or the slop p i ng of lead through t he co e v r doors .

The water cup s occasi onally become clogged wi th lead and have to be freed by a
sp eci al p unchi ng rod i n th e hands of thrman
e ba .

Lead soon freezes to a crust on t he upp er ri ng of the kettle and to the cover Peri .

odi cally the w at er i s t urned off t he cover doors are t hrow n back and the crusts barred
, ,

dow n w i th a 6 ft steel bar 1 i n i n di am

-
. et er havi ng a chi sel p oi nt
,
. Consi derable , .

j g
ud m en t m ust be ex erci sed not to allo w t he cr ust s t o beco m e t oo th i ck as i n t hi s ,

case i t i s di fficult to break themup w i th th e st eam and they tend to formch unks ,
.

Also too f req uent barri ng dow

, n consum es ti m e as the w at er has to be t urned ofi ,

duri ng that p eri od .

I n order to facili tate barri ng dow

°

n the i nsi de of the cover and the upper ri ng of ,

the k et tle should be as smooth as i t i s p ossi ble to make them .

Soon cryst al s of lead fromM3 to 36 i n i n di am et r begi n to ap p ear i n t he bath

, . e , ,

and fromth i s p oi nt on th ey multi p ly wi th eve i ncr a i ng rap i di ty the vi olent agi t a r e s ,

ti on by t he steamkeep i ng the cry tals f omadhe i ng t o ne anot her s r r o .

W hen the wo thi rds crystals has been reach ed t he surface of the
consi stency of t -

lead ap p ears as an exceedi ngly thi ck mass of boili ng cryst als At t hi s stage th e water .

i s shut ofi the ket tle barred dow

, n for the last t i me and the crust s broken up by steam ,
.

Steamis nowturned ofi the ket tle elevat ed and tw o hot sp outs just out of the spout
, ,

kettle are p laced on the double lead cocks These cocks ( whi ch are kep t hot wi th
,
-
.
 BE S ILVERI ZATI ON OF LEAD B ULLI ON 493

c harcoal) are op ened slo wly

and th e one thi rd of t he ch arge i s tap p ed to t he adjoi ni n
, g
-

kettle th rough a screen i n the bottomof the kettle coveri ng the double tap s This .

screen has 96 holes 94 5 i n di am eter 2 i n cent ers

1 -
. . .
,

As soon as the last crust has been barred dow n the burners are start ed and by the ,

ti m
,

e the li qui d has run out the tem p erat ure i s rap i dl ri
y si ng
“ .

Under the p rop er condi ti ons a ket tle can be crystalli z ed i n 1 5 m i n An average
, .

op erati on cryst alli zi ng and tap p i ng requi res about 30 m

, in , .

It w ill be noted fromthe cycle di agramthat any del ay on one ket tle afi ects the
whole plant Qui ck crystalli zi ng and qui ck melti ng are therefore necessary to speed
.
,

and the m ore rap i dly these op erati ons are p erform ed the few er kettles need i ntervene ,

bet ween t he k ettles th at are bei ng op erat ed Th us m ore k ettles can be i n op erati on .

at th e sa me ti me .

O n t he wo crews are op erati ng si multaneously whereas on the long

h
s ort stri ng, t ,

stri ng as m any as four crew s m ay be w orki ng .

As soon as t he crystal s are m elted t he lead i s ski m med and tap p ed to th e op posi te ,

adjacent k et tle through th e si ngle lead cock w i thout a screen The average m elti ng -
.

p eri od i s abo ut 4 5 mi n Th i s co m p let es an

“
o p erati on
”
. .

The k et tles near t he corrodi ng end are m uch m ore di fficult to op erat e than those

near the anode end ; also the fini shed lead at t he anode end ap p ears m , uch thi cker than
that at the corrodi ng end Thi s i s due to the crystals near the anode end bei ng larger
.

than those at the corrodi ng end of the p lant .

2 2 9. —
Dross, Fuel, Labor, Cost Dross i s one of the most objecti onabl e features of
a Pat ti nson p lant . I n the early st ages of t he T redi nni ck p lant , 2 1 p er cent of t he lead .

cha rged was ski mm ed 06 as dross Thi s w as not onl y exp ensi ve to handl e, reduce, and
.

recharge but i t also left the lower kettles short of lead

, ,
and th ereby educed the tonnage r
mat eri ally .

was found that throwi ng small quanti ti es of fuel oi l i nto th e kettle on top of
It
t he cryst als duri ng t he melti ng p eri od hastened th e m el ti ng and reduced th e dross ,

formed duri ng the crystallizi ng .

H andl ed i n thi s manner t he reduci ng reverberatory furnace needed to be op erated

,

only 4 or 5 days a m onth and the lead rem ov ed as dross am ounted to not m
, ore th an

2 to 3 p ercent of the lead ch arged . .

Duri ng th e crystallizi ng, about 50 lb of li tharge, fine as flour, is form ed, w h i ch i s .

draw n ofi by the telescop e fum e p i p e, and caught i n the fine A very strong draf t i s -
.

necessary to k eep thi s fu e f ro p a ssi ng t hrough th e cov er doo rs and m

afi ect i ng thme

health of the men .

The fuel re ui re ment

the p lant dep end up on the nu ber of op erati ons
q s of An m .

average of 50 gal of fuel oi l i s req ui red p er op erat i on

. Of thi s, 4 0 gal p ass through . .

the burners and 1 0 gal are th row n on top of the el ti ng crystals i n the k et t le
. m .

— m
Laban The acco p anyi ng labor table is based on a cre sufi ci ently large to w
m ak e fro 50 to 70 m
op erat i ons each 2 4 h r
”
.

l For so me ti me
hydrauli c p ress ( U S Patent, No 9 654 64 , July 2 6, 1 9 1 0 ;
t he H ulst . . .

Eng M i n J , 1 9 1 0, x c, 853 ; and U S Patent , N o 1 00 1 52 5, Aug 2 2 , 1 9 1 1 ; Tr A I M E ,

. . . . . . . . . . . .

1 9 1 4 , x u x , 53 7) was i n operati on i n order to hast en t he flowof li q ui d lead, and t o obtai n

cleaner crystals .

It i s howaccurately a good crystall i zer can j udge the p rop orti on of li qui d
surp ri si ng

and crystals i n t he fini shed ket tle A good an w ill seldo be i n error over 2 t ons, and . m m
thi s i nequali ty ay be eli m m
i nated on a subsequent operati on by sli ghtly over or under .

crystalli zi ng as th e case my requi re a .

494 ME TALLU mY O F LEAD

T AB LE 1 r7 —.LAB O R

No . men
Day shi ft ( 10 -
1 2 hr ) .

1 General foreman
Burnerman
Burnerman assi stant

Crystalli zers
Barmen
Barman i n traini ng

Tap p i ng and cleani ng ket tles

Crane -
man
Clean -
up and general utili ty

I n charge at lap and noon ti me

Crysta lli zer i n trai ni ng

1 75 Bar men i n trai ni ng

N i ght shi ft Sa me a s above

Reduci ng furnace
1 $ 2 . 00 Furnace -
mn a , 5 day p
s er ont h m
1 Furnace -
man helper, 5 days per month .

3 Dross , 5
men
days p er month
1 D ay superi ntendent .

1 N i gh t superi ntendent
Total p er mntho

1 Fi ve men co mi ng o n at 9 . and worki ng unt i l 7 o clock

’
.

Cost — An 1 1 -
ket tle p lant , as descri bed, treati ng fro m 1 5 to 2 00
0 tons lead i n 24

hr ,. costs about The cost of an Op erat i on is about whi ch figure includes

all o verhead expenses , such as i nsurance, taxes, a mo ti r zat i on, royalty,
general exp ense .

In co mp aris on wi th th e Parkes p rocess verage cost p er ton lead bulli on

th e a

charged moderate si e p lant

in a -
z t reat i ng lead bulli on w i t h 1 00 oz Ag p er ton wi th .
,

zi nc at a normal figure of 5 cts p er lb is about $4 p er ton

mP oce
. .
,
.

2 30 . Th u process wh i ch has not yet b een carri ed out

r ss .
1
In t i s
h
,

i n p rac ti ce the l ead contents of stati onary k ettl es are to be transferred fro mone
,

t o ano th er by m eans of com p r essed ai r thro ugh r i si ng p i p es h ea ted by el ec tr i c

resi stance co i ls wo und around them .

PARKE S PRO CE S S

2 31 . l Park es process is based on the fac t that

Park es Process, Genera . — ’

i f fro m1 to 2 p er cent Zn i s sti rred i nto mel ted l ead b ulli o n i t wi ll depri ve
.
,

t he lat ter of i ts Ag and for man alloy wh i ch b ei ng less fusi b le th an lead and
, , , ,

havi ng a lower sp ec i fic gravi ty wi ll b ecome h ard and float on the surface of ,

the lead wh enc e i t can be r em

, oved and treated separately ; the lead whi ch ,

1
U S Patent No
. . . 1 1 064 80 , Aug . 1 0. 1 904 .
496 ME TALL URGY OF LEAD

The crust whi ch forms i n zi nc desi lveri zati on contai ns from30 to 50 per cent .

Pb ; h ence t he th eory has b een p ut for th that t ernary all oys of Zn Ag and , ,

er e for m In prac ti ce i t i s co m mon to speak of the zi nc si lver lead

“
Pb w ed .
- -

cr ust
”
. Krem ann and H ofm ei er i nvesti gated th e po ssi ble ternary al loy s and
l

came t o the co nclusi on that i n zi nc desi lveri zati on no ternary alloys w ere
formed that the formati on of the compound Aga s caused desi lveri zati on ;
,

th at Ag, Zn5 form ed soli d sol uti o ns w i th Zn but not wi th Pb; and th at the Pb ,

i n the cr ust w as a m ech ani cal adm i xture They b ased thei r research i n p art .

upo n the i nvesti gati on of Pet renko who se freezi ng poi nt curve showed fo ur
2 -

chemi cal compo unds of Zn and Ag vi z Aga 5 wi th 60 p er cent Zn ; Ag, Zn3 wi th ,

. .

8
4 p er c en t ; A a w i t h .
p er c en t ; an d A gsz n z w i t h p e r c en t Z n . . .

The c urve of Pet renk o has b een super seded by

the co nsti t uti onal di agram of Carpenter and
“
Whi teley g i ven in Fi g 4 87 ; Petrenko appar .

ently havi ng acc ep ted the correc ti on Fi g 4 8 7

‘
. .

sho w s si x consti t uents : A soli d sol uti o n a wi t h

fro mo to abo ut 2 7 p er cent Zn stable at ordi .

,

nary t em perature; a fi soluti on extendi ng fro m -

abo ut 2 0 t o abo ut 4 8 p er c ent Zn stabl e onl y .

,

above 2 64 C below whi ch i t undergoes an °

.
,

eutec ti c t ransfor m ati o n i nto a + 7 ; a chem i cal

m
A g Per Oent

FI G 4 8 7 — l i
A oy se es Zn
l
co po u n d w i th 4 8 p er c en t Z n f re ez .
,

i ng at 665 C ; possi bly a second chem i cal com

. r .

°
.

po und Aga s wi th 60 p er cent Zn freezi ng at 636 C whi ch forms soli d .

,
°
.
,

sol uti o ns on the zi nc si d e; a co nsti t uent e stabl e o nl y at hi gh tem peratures ,

whi ch spli ts i nto 6 and n at lower temperatures ; soli d soluti ons of Zn wi th

not m ore than 1 p er c ent Ag Zi nc desi lveri zati o n therefore finds i ts . .

expl anati on i n the for m a ti on of the ch em i cal co m pound Aga s w i th 4 8 p er

c ent Zn freezi ng at 665 C The Pb present i n the crust i s a mechani cal
.
,
°
.

ad m i xt ure of Zn b eari ng Pb w
— hi ch o wi ng to superfici al o xi dati on both of Zn Pb —

and Ag2Zna c annot be sati sfac tori ly separated by li q uati o n .

Thi s tend ency t o oxi dati on has been co unterac ted by E d el m ann and

Ro ssler ‘
by the addi ti o n of 0 5 per cent Al to the Zn whi ch resul ted i n a
, . .
,

cr ust ri ch i n Ag and poor i n Pb Thei r process has been ab ando ned as t he 6

.
,

presenc e of p er c e n t C u of p e r c e n t A s a n d of 1 p e
.r c en t S b n e u
, .
,
.

trali zed th e beneficent efi ect of Al ; the pr esenc e of p er c en t S b w a s h ar m .

Momb heft fur Chemi e, 1 9 1 1 , xxxn, 563 , 59 7 ; Mi n . I nd .

,
1 9 1 1 , xx , 4 93 .

Zt . anorg . Che m .
,
1 906, X LVIII , 34 7 .

I nternal Z t Mctallogr , 1 9 1 3, m 45; J In t M 1 s et 1 9 1 3, lx , 2 1 4

m
. . . . .
. .
, ,

J . Russ P hys Che . . m S oc

. .
,
1 9 4 mm 75 ; J S
1 , ,
1 . oc . Che m I nd . .
,
1 91 5, xxx , 1 21 1 ; Che m .

Abstr ,.
5, lx , 7 77
1 91 .

“Berg H fi uen Z , 1 890, x u x , 2 4 5, m 2 4 9 ; 1 89 1 , L, 1 2 3 ; E ng Mi n J 1 890, L, 573 ; 1 89 1 ,

m
.
. . .
,
. .

58 2 ; 1 893 , , 2 4 5, 44 7. 568

Loui s “ andbook Metallurgy,

Schnabel H of 1 905, 1 , 688
m
-
.
,

Schnabel, Berg H i . mm Z . .
,
1 89 7, LVI , 39 , 4 0 .
 DE S ILVERI ZA TI ON OF L E AD B ULLI ON 497

les s H asse replaced the o 5 per cent Al by 0 3 per cent Mg and ob tai ned
.
l
. . . .
,

resul ts si milar to those of E delmann and Rossler .

Th ere exi sts as yet no defini te i nformati on as regards the sol ubi li ty of Pb

i n Aggl ng 01 Of Aggl na i n PD '

.

2 Gold — The co nsti tuti o nal

. . di agramof the alloy seri es Zn Au,
-
drawn by
Vogel gi ven i n Fi g 4 88
’
and AuZn Auszns .
,
sho w s three ch emi cal compounds , , ,

and Aua wi th freezi ng poi nts at ,

and -

49 0
°
C an d n o sol i d
. sol
, u ti o n s T h e co m po u n d s Too 8 0 oo 40 20 o .
'

Anzu and AuZ n; f urni sh a sati sfactory explana

ti o n for Au bei ng taken up by Zn ; i n fac t i t com ,

bi nes w i th Zn m ore readi ly than does Ag I t used .

to be com mon practi ce to add to the Pb bath -

eno ugh Zn t o satur ate the Pb and to rem ove all the
Au wi th som e Ag and to t reat thi s Au crust sep a ,
-

rately fro mthe Ag crust Thi s m ethod of worki ng -

.

has been ab andoned i n the Uni ted States but i s ,

sti ll i n oper ati o n i n so m e E uropean and Aust rali an

refineri es
m
m
.

— 9° W
3 C o . a Th e fre ez i n g po i n t c urv e of the ”
m gn g“ -

- —
all oy seri es Zn Cu of Shepherd and Tafel 3 ‘
repro F10 4 88 — Alloy seri es Zn Au ,

shows the exi st ence of the com

-
. . .

duced i n Fi g .

°
po und Cua a freezi ng at 830 C whi ch i s probably the cause of Cu readi ly
,
.
,

enteri ng th e crust In fac t Au and Cu co m bi ne wi th Zn before Ag It may

. .

be no ted that the alloys of Au and Cu formsoli d sol uti ons througho ut
6
The .

Au crust m
-
enti oned above i s alw ay s ri ch er i n Cu th an the sub sequent Ag cr ust -
.

P cm 0“ L a rg e.,sca l e t es t s h av e s
,
ho w n t h at co ns u m p t i o n -

of spel ter i ncreases wi th the Cu co ntent of the -

Pb; i t becom es no ti c eable wi th p er c e n t .

Cu I t i s therefore of greatest i m portance to .

melt bars of lead bul li on slowly in the reverbe

ratory f urnac e or k ettl e and to dro ss t he lead ,

carefully so that most of the Cu may be removed

by ski mmi ng before the ad di ti ons of sp el ter are
0 1° 2° 8° 9° 1110
made In the endeavor to i ncrease tonnage thi s .

FI G 4 89 — Alloy seri es Zn Cu
i m p or ta n t fe a t u r e h as of t en b ee n ov e rlook e d .

If li qui d l ead b ul li o n i s t r ansferr ed fro m the

-
-
. . .

blast furnace to a kettle i t i s i mpor tant to allo wi t to cool to the requi red ,

degree So me refiners remove from the surface all the dross that can be
.

1
Op . ci t .
,
1 89 5, mv , 4 83 ; Mi n . I nd .
,
1 89 5, N ,
8
4 3; Z t B erg.H ill S al . . . W . i Pr ,
. . 1 89 7,
X LV, 3 3
2 .

Zt anorg m 906 v 3
Che 1 ,
23 .

Ch m 904 vm 4
.
. .
, ,

J . P hys . e .
, 1 , ,
21 .

MM argi e, 1 90 8, v, 34 9 .

“
Exp lanati on detai ls, see H of an, Cop per, 1 9 1 8, p 2 8 of m . .

Roberts Austen and Ki rk Rose, Proc Roy S oc , 1 90 1 v n, 1 05

- -
. .

m
. .

KurnakowSche tschuschny, Zt anorg Che , 1 907, U V, 1 64 -

m . . . .

82
4 98 ME TALLURGY OF LE AD

ski mmed readi ly allow the lead to soli di fy remel t slowly and ski magai n
, , ,
.

The sol ubi li t y of Cu i n Pb has been taken up i n § 8 .

4 P.la ti n u m a nd P a lla di um — B o t h m e ta l s a r e coll ec te d i n th e cr u st A c .

cordi ng to Devi ll e and Debray Pt forms the compound Pt ,Zn3 ; they fai led to
l
,

find a si m i lar co m pound for Pd ’

.

The entrance of Pt m etal s i nto t he crust m ay also be favored by the so li d

sol uti o ns of Pt w i th Au
a
Ag and Cu ; of Pd w
‘ °
i th Au Cu and Ag; and of
‘ ’ ‘
, , , ,

Pd wi th Pt ’
.

m — o H eberlei n s m
lo
5 T
.e llu r i u A ccor di n g t t h i etal readi ly enters the c rus t .

H e fo und th at wi th lead b ulli o n co ntai ni ng p e r c e n t T e a n a d di t i o n of .

,

1mo m m 5 p e r c en t s p e
.
l t er c a us e d
.
9 5 p e r c en t of t h e . .

100 so 50 40 so Te to ent er the cr ust The c urve of Kabayashi "

.

shows th e ch em i c al com po und TeZn freezi ng at ,

°
1 2 38 C wi t h eutec ti c poi nts very clo se to th e .
,

end s of the seri es .

6 B i sm uth — Thi s m etal does not enter th e .

cr ust ; the desi lveri zed lead r uns hi gher i n Bi

th an di d the ori gi nal lead b ulli on In one case "
.

so 0 so no the Bi co ntent of the refined lead rose fro mthe

32
-

»
usual figur e of to r c e nt d u r i n g
Fm
l
ii
.

—
Zn B 1
a peri od w hen lead bul li on runr ng hi gh i n Bi
’ .

was bei ng desi lveri zed Another example i s gi ven i n Table 1 1 9 The c urve . .

“
of H eycock and Nevi lle supplemented by the researches of Spri ng and ,

and Arnem gi ven i n Fi g 4 90 shows co nj ugate soluti ons

15
ann , .
, ,

an eut ecti c w i th p e r c en t Z n fr e ez i ng a t C a n d a s li gh t s ol u b i li t y .
,
.
,

of Bi i n Zn Thi s explai ns the tendency of Bi to rem

. ai n wi th the Pb and no t

to be tak en up by t he Zn .

A i — h c rv of ri d ch L ro g i v i i ho w h
m
7 .r s e n c T e u e F e ri a n d e u x e n n F g 49 1 s s t a t ,
.
,

the tw o m etals h ave no a ni ty w hatever ; hence As w i ll not enter the cr ust It .

Ann M i n , . . 1 859 , xvr, 33, 5 1 .

See also Co mpl . rend , 1 88 2 , x crv, 1 55 7 .

3
Doeri nckel , Zt . anorg . Che m .
, 1 90 7, L1v, 34 7 .

Doeri nckel, loc ci t 34 1

m
. . .
,

Tho mon s and Miller , J m Cha n S oc 906

. A . . .
, 1 , xxv , 1 1 1 5.
5
Doeri nckel, Z t . anorg . Chem 90 7 LIV 33 7 .
, 1 , ,
.

Ruer, op . 1 906, LI , 393 .

7
Ruer, lac . ci t .
,
2 25 .

3
Ruer, loc . ci t 3 1 6
mm 34
. .
,

Puschi n -
Laschi tschenko, op . cit .
,
1 909 , , .

Rudolp bi , op . ci t .
, 1 9 1 0, v n
,
65 .

1° B erg H iale n Z m 1 89 5, LIV, 4 2

m
. . .
, .

l l Kyoto, M orn Coll S ci ence, I mp U ni v K ot

y , 9 ,
o 1 1 1
. . . .
,
21 7; J . 1 9 1 1 , V1 ,

Junge Freiberg Jahrb 1 89 5 p

, . .
, ,
.
3 .

1 ’ J Chem S o
. c 1 89 7 L100 394 . .
, , , .

N Zt . anorg . Che m .
,
1 89 3, x m , 2 9.
1‘ M etallurgi e , 1 9 1 0, V11 , 2 01 .

N Metallurgi e , 1 906 , m 4 77 , .
500 ME TALLURGY OF LE AD

TAB LE 1 19 — Cru nch es

. mL E AD B U LLIO N BY D noss m o AND c mo
x

Co mposi ti on of lead bulli on

In the Uni ted States, refineri es recei ve lead b ulli on greatly varyi ng i n i ts
Sb co ntent
-
It i s th erefore the general prac ti c e to rem
. ove the Sb by an oxi diz
i ng fusi on i n sof teni ng before zi ncki ng Anti mony does not i nt er .

fere wi th the work of the H oward press

m 8 1 1

l oo so so ro oo so wso 20 10 o as does arseni c

'

9 Ti m — T hi s m et al r em a i ns w i t h t he l ea d .
,

as can be seen fro mthe freezi ng poi nt c urve of -

H eycock N evi ll e and Arnem

l
ann
’
gi ven i n Fi g -

,
.

4 93 w hi ch sho w s a n eu t ec ti c w i t h 0
9 p e r c e n t , .

Sn freezi ng at 1 98 C a soli d sol uti on of Zn i n

°
, .
,
o 10 ”
1 30?
0 8° so 190
3 1
S n to
55 t h e e x te n t of a bo u t 2 p e r c en t b u t n o .
,

Fro 4 93 .
— .
—
Alloy seri es Zn Sn chem i cal com -
po und Ti n i nterferes wi th zi nc .
.

desi lveri zati on and has to be removed by

sof teni ng the l ead b ulli on

These tw o m
1 0 N i ckel cobal t
.
— -
etal s occ ur very sli gh t ly i n l ead b ulli o n ;
.

the sm all am o unts present are co mpl etely removed by car eful drossi ng so that
t hey need not be c onsi d ered i n regul ar w ork If drossi ng has not been well done .
,

and so m e Ni and Co r em ai n wi t h the lead

em 2
:

I , ,
.

they mght enter the cr ust as Ni form

" .

i s the
o “
100 90 8° 70 0 0 50 1o 30 20 10 0
,

compound Ni Zna freezi ng at 876 C and Co 5 3 3

,
°
.
‘ ‘

t e co po
h m u n d Go 4 free ng at 8 73 C
z u z i ‘
ii 300
, .

1 1 S um mary From the well establi shed 33

.
— -

behavi or i n zi ncki ng of the metals consi dered

1

10 “0 ” m wr 8° w
,

and fro m the freezi ng poi nt c urves di sc ussed g e fe e

1115
-

, a -

the concl usi o n appears j ust ifiabl e that only a Fro 4 94 — Alloy seri es Zn Cd — .
-

metal whi ch forms a chemi cal compo und wi th

. .

Zn i s li k ely to enter the cr ust and that an eutec ti c ac ts i n the opposi t e ,

di rec ti on .

12 S pelter
.
— The spel ter used for desi lveri zati on o ugh t to be p ure
. .

1
J . Che m S oc . .
,
1 89 7, m
m , 3 83 .

M etall urgie 1 9 1 0 vn 2 0 1 , , , .

3 Tafel M clall ur i e 1 0
g, 9 7 IV , , , 784 .

Voss Zt anorg Chem 1 908

,
. . .
, ,
LVII , 68 .

‘
Lewkonja op ci t 1 908 L131 , . .
, , , 3 2 1 .
 DES ILVERI ZA TI ON OF LEAD B ULLI ON 501

The efiect of Cadmiumi s negli gi ble . It forms , as seen i n Fi g . an

°
eutecti c wi th p e r c e n t C d fr ee zi n g a t 2 70 C .
, .

The case i s di fierent w i th I ran w hi ch as sho wn in Fi g 4 95 forms two chem

1
, .
,

i cal com po unds FeZn7 at 662 C and FeZns at 770 C as well as a soli d soluti on ° °
-
. .
, , ,

of Zn wi th er c en t F e T h e pr e senc e of Fe i n Zn i s th erefor e h ar m f u l
p . . .

Practi cal experi ence wi th Fe b eari ng sp el ter by Jernegan Fohr the wri ter ’ 1 ‘
-

, , ,

and o th ers has shown that the zi nc co nsum p ti on i s much greater i f the Zn con ,

t ai ns Fe Thus F6hr found that he requi red fo ur ti m

. es the nor m al q uanti t y of

spel ter wi th a b rand co ntai ni ng Pb F cm 2 ”

5 e ,
.

Cu c S A S b S d S d 10°
"

er en t n a n 95 90 85 80
p s .
, , , , , ,

C tr aces In analyses of good b rands Fe ap

.

pears onl y i n the second deci mal .

1 3 Conclusi on
.
— From what has been sai d .

regardi ng the behavi or of the metals fo und i n 03100

1
lead b ulli on and spel ter i t i s seen that both ,, ,

must be reasonably free fromharmful metals 5 , ,

if desi lveri zati on i s to proc eed i n a sati sfactory 55m

way Tests made by Ki rchhofi on lead
.
5

b ulli on contai ni ng 4 5 per cent forei gn metals 100 . .

,

such as Cu As Sb Bi and Zn showed that , , , , ,

p er c en t z i nc w as r
. eq u i re d t o d e si lv e ri ze t h e
Pt: F
”
.
l ead when the b ulli on had not been softened Fm 4 9 5 — A11oy senes Zn Fe ,

w
-

whereas
.

5 p er c en t a s sufi a e n t 1f s of t en .
,

i ng had prec eded t he desi lveri zati on ; the relati ve q uanti ti es of m ark et l ead

p roduced were 4 3 per cent and 72 per cent of the lead b ulli on charged . . .

Table 1 2 0 sho w s how the si lver contents decr eased w i th each addi ti o n of
zi nc .W i th the cr ude lead the fir st five zi nc addi ti ons served onl y to r em ove ,

t he i m p uri ti es to such a degree that the desi lveri zati on co uld b egi n Th at .

t he first ad di ti on of zi nc to the sof tened lead took up so li ttle si lver shows

that the lead m ust have b een very copp ery .

The fo ur m etal s t hat i nterfer e pri nci pally wi th desi lveri z ati o n are Cu Sn , ,

As and Sb ; the fi rst i s sufi ci ently rem

, oved by drossi ng the o ther three by an ,

oxi di zi ng f usi on .

As regards spel ter m ost of the metal ob tai ned fro mthe smel ti ng of ores ,

runs sufi ci ently low i n Fe to make i t sui ted for the Parkes process ; thus Pri me
W estern w i th Pb 1 50 p er cent and Fe p er c en t i s th e gr ad
. e or di nar i l y . .

used The zi nc r ecov er ed fro mthe treatm

. ent of dro sses scr ap et c i s usually , , .
,

worthless An analysi s for Fe answers the q uesti on of sui tabi li ty i n al most

.

all cases .

H eycock Neville J Chem S oc 1 89 7

1 -
8
3 3 , . . .
, , .

Hi ndri chs, Z t . anorg . Che m 907 .

, 1 W 41 7 .

m 37
, ,

Vegesack ,
op . ci t .
, 1 90 7, , .

Arne mann , M etallurgi e, 1 9 1 0, vn , 2 01 .

3
Tr A I . . . M E . .
—
1 8 73 74 , 1 1, 2 88 .
,

Berg H utten. mZ . .
, 1 888, XLVII ,
28 .

Metallurgi col Revi ew,

1 877 -

78, 1, 2 2 4 .
502 ME TALLURGY OF LE AD

TAB LE 1 20 — . D ES I LVE RIZATI ON or NON -

m NE n
so I up r m E LE AD BU LLI ON

Lead bulli on
So ftened
m
N u ber of addi ti ons of zi nc

Af ter drossi ng

Outli ne of
2 33 . Process — In the Park es process the lead bulli o n usually
,

recei ved i n bars, i s first drossed so as to remove all the h arm

melted and , ful
meta ls whi ch can be separated by li quati on and then subj ec ted at an elevated ,

tem perature to oxi di z ing infl uences to oxi di z e the remai ni ng i m p uri ti es and
volati li z e as w ell as scorify themwi th the li tharge formed whereupon th ey can be ,

removed by ski m ming The whole Operati on goes by the name of S ofteni ng
. .

The com mon Ameri can prac ti ce i s to sof ten the lead b ulli on in a reverberatory
furnace; i n some cases mel ting i s carri ed on i n a k ettle and li quated li q ui d ,

l ead b ulli on th en transferred to a reverberatory f urnace for the oxi di z ing fusi on .

I n som e E urop ean work s a li q uati ng reverb eratory f urnace i s used for m el ti ng .

Oxi dati on of li quated lead b ulli on at an elevated tem perature i n a k ettle by

sti rr i ng wi th steami s unsati sfac tory as the anti m ony skimming qui ckly cor
,

rod es the kettle and the amo unt of sk i mming formed i s excessi ve
,
.

The sof tened b ulli o n i s di scharged i nto a k ettle i n whi ch i t i s desi lveri z ed .

Th e desi lv eri z ed lead has to be freed fromthe to p e r c en t Z n wh i ch .

i t retai ns b efore i t can be used i n the m

,
etal i ndustri es Thi s operati on called .
,

Refini ng i s carr i ed on ei th er i n reverb eratory furnaces by m

,
eans of an o xi diz i ng

fusi on at an elevated tem perature or i n a kettle by means of steamwhi ch at

,

9 0 0 t o 1 000 C
°
i s d e
.co m po se d by t h e z i n c co n tai ned i n th e l ead T h e r es u l t .

of bo th Operati o ns i s refined l ead and an i ntermedi ary oxi de prod uc t Th e .

l ead i s m olded i nto bars fro m the furnace di rec t or goes first into a mark et
k ettle The intermed i ary p roduc ts i a drosses softeni ng ski mmi ngs and re
.
,
. .
, , ,

fini ng sk im mi ngs or oxides are worked up separately ,

.

The zi nc crust wh i ch contai ns co nsi derable am

,
o unts of lead besi de th e zinc
and prec i o us m etals i s di sti lled i n r etor ts to recover as m
,
uch zinc as po ssi ble ,

to be used agai n and an enri ch ed r etor t b ulli on wh i ch i s c up elled for silver

, ,

(p erh a p s doré ) a n d l i th arg e Th e i nt e r.m edi ary pro d uc ts fro m di sti ll a ti o n

504 ME TALL URGY OF LE AD

( bl ue powd er a nd dro sses) and cupellati on ( li tharge and cupel bo ttom)

-
are

work ed up i n a sui table manner .

Th i s bri ef o utli ne i s shown wi th so m detai l i n th

e e flowsheet -
g i ven i n Fi g .

4 96
2 34 .Plant, General —
general plan of a desilveri zing plant vari es
. The
so m ew hat wi th the locati on and the prevai li ng prac ti ce of operati ng All .

arrang em ents however have to be of such a ch arac ter as to r eq ui r e as li t tle

, ,

handli ng of lead and i ntermedi ary prod uc ts as po ssi ble In fac t the grea ter .
,

par t of the lead wh en once charged i nto the softeni ng furnace will not be
, ,

handled agai n i n a mod ern plant unti l i t i s ready for shipment The result .

i s th at a v er ti cal sec ti on thro ugh a refinery wi ll sho w a num ber of terraces

on wh i ch are p laced the apparatus i n the order req ui red by th e process Th i s .

i s th e case wi th three of the exam ples gi ven below Si nce the handling of .

molten lead by means of the Mi ller centri fugal pump has co me into use ,

the num ber of terraces has b een red uced as shown i n the fo ur th exam ple , .

Mo st E urop ean plants are al tered Patti nson batteri es and are therefore
b ui l t on a hori zonta l plane Th i s arrangement has advantages as regard s
‘
.

pri mary co st and perh aps sup ervi si on and control work but the operati on ,

canno t but be more exp ensi ve D rawi ngs of the refinery at Montepo ni .
,

Sardi nia have b een p ubli sh ed by Ferrari s

,
2
Belo ware gi ven drawi ngs of fo ur .

terrac ed plants wh i ch m ay serv e to r ep resent m od ern prac ti ce

2 35 Nati onal Sm
.
,

. elti ng and Refini ng Co South Chi cago, Ill 1— Thi s plant . .

was erec ted i n 1 889 by F B F Rhod es ; i t was tak en over i n 1 899 by the . . .

Am eri can Sm el ti ng and Refini ng Co and und erwent several changes b efore .
,

it w as clo sed i n In Fi gs 4 97 and 4 98 are gi ven a ver ti cal sec ti on .

and plan of th e ori gi nal plant Tho ugh i t i s sm all wh en com pared wi th o ther .
,

works having only two 3o ton kettles and has li quating kettles whi ch have
,
-

become ob sol ete since the i nventi on of the H oward press i ts leadi ng features ,

were excellent wh en b ui l t and are wor th followi ng today On the hi ghest , .

level are two softeni ng furnaces whi ch recei ve each 40 tons lead b ulli on ,

and prepare i t for the tw o 30 ton k ettles The latter are a stage lower and -
.
,

there the sof tened bulli on i s desi lveri z ed Th e apparatus for li q uati ng z i nc .

crusts i s also upon the sam e floo r In the drawi ng each desi lveriz ing kettle .
,
-

has close to i t only one li q uati ng k ettle wi th a sm all k ettle for li q uated l ead , ,

showi ng th at no di sti nc ti o n i s m ad e b etw een gold and si lv er crusts If th e .

H ow ard pr ess be used the li q uati ng k ettl e or li q ua ti ng reverb eratory furnace

,

wi ll not be req ui red The li quated cr usts pass fromth i s floor i nto an adjoi ning
.

b ui ldi ng placed to the ri gh t or the left of the m

, ai n b ui ldi ng the floo r of whi ch ,

is on a level wi th the scale floor It contains tw o d epar tm ents — the retor t -

.

1 Roesi ng, Zt B erg H u . . m » . 8 01 . W . Pr , . 1 888, xxxvr, 1 03 ; B erg H utten . mZ

. .
, 1 888,
XLVII . 33 7
Saeger, Zt B erg B atten S al
. . . . W i . . Pr ,. 1 89 3, m ,
2 68 ; drwg . of Tarno i tz plantw .

1
Oesterr, Z t B erg fl utters
. . 1 905, Lxxx , 4 55 ; E ng . Mi n J . .
, 1 905,
a n, 4 55 .

1
Pulsifer M i n E ng World
, . .
,
1 9 1 3 , xxx vr, 1 53 , 2 05 .

Pulsi fer op ci t 1 9 1 5 X LV
. .
, , ,
1 6 .
 DE S ILVE RI ZA TI ON OF LEAD B ULL I ON 505

roo m where the crusts are di sti lled and the cupelli ng room wh ere the retort
, ,
-

b ulli on i s turned into si lver or doré si lver bars In the plant shown in the
,
-

, .

figure only doré b ars will result Follo wi ng the desi lveriz ed lead th e r efini ng
.
,

furnaces are reached on the next level i n whi ch the d esi lveri zed lead i s de ,

zi nckifi ed Th enc e i t p asses i nto the m

. erch ant k et tles and fro mth ese i nto -

the m olds placed in the lead p i t The mark et lead i s loaded on trucks on the-
.

scale floor th at are of th e sam

-

e construc ti on as th e b ulli on—recei v ing tr uck s ;

th ey are run on scales and the wei gh ed lead i s transferred i nto the cars on the
,

l eale 01 Feet

FI GS .
497 and 4 98
— Secti on and plan, Parkes plant, N ati onal S
. melti ng 81 Refining Co .
,

South Chi cago, Ill .

loa di ng track -
The pl
. for work i ng the by prod ucts i s placed on the si d e
ant -

of the m ai n b ui ld i ng , oppo si te that wh ere the z i nc crusts are tr eated The -

mann r e of deali ng wi th these vari es gr eatly in di fferent refineri es, and wi ll

be di scussed later on

melti ng and Le
.

2 3 6. S elby S ad Co , S elby,
. CaLQ Th i s p lant was erec ted
in 1 884 and i s in
ccessful operati on at present
su elevati on i s . A sec ti onal
gi ven i n Fi g 499 On the tOp floor are two 60 ton oi l fired softeni ng furnaces
. .
- -

and tw o track s on wh i ch travel the tr uck s wh i ch bri ng the lea d b ulli on fromthe
sm el ti ng d epar tm ent The sof teni ng furnac e floor and the colum
. ns suppor ting -

1
Ri ckard, Mi n S c Press, . . 1 9 1 6, c m5 ,
05 .
ME TALLURG Y OF LE AD
508 ME TALLURGY OF LEAD

bulli on arri ve on a a 1 00 ton tr ack scale; fromthe m

track provi ded wi th -
ai n

track branch ofl five storage track s f urni sh i ng space for 1 00 cars The pri nc i p a l
.

operati ons are carri ed on i n the si ngle main b ui ldi ng a steel struc ture 4 80 by 1 80
, ,

ft and 50 ft hi gh wi th three levels shown i n Fi g 500 on whi ch are broad gauge

. .
, , .
,
-

tracks . Two 1 5
-
ton l c tri c cranes of 2 8
ee and 77 ft s p a
-
n , c ov
.eri ng the ke t t l e,

and th e r efini ng and moldi ng di vi

ons travel
si , the enti r e leng th of the b ui ldi ng .

The m ai n battery contai ns tw o sam p l e k ett

-
l es of 45 to ns cap ac i ty ; two 60

ton li q uati ng k et tles ; two 300 ton sof teni ng furnac es ( 1 3 ft 6 i n by 2 8 ft 2 i n

-
. . . . .
 DE S I LVE RI Z A TI ON OF LEAD B ULLI ON 509

and 3deep
1 in . tw ,
Fi gs 51 7
d lv . o 1 00 -
ton esi e rizi ng k ettles ; one 300 ton -

refini ng f urnace me si ze as the sof teni ng furnaces; and one 2 00 ton

of the sa -

moldi ng reverberatory furnace For the treatment of i ntermedi ary prod uc ts .

th er e are provi d ed : three r esi d ue r everberatory f urnac es ( 8 by 1 6 ft and 2 0 .

—
i n deep insi de Fi gs 63 1 634 ) of 30 tons capaci ty for c0p p er dross and anti .
.
, ,

mony ski mmi ng li tharge and si lver free refini ng ski mmi ng ; two ci rcular water
, ,
-

j acket blast f urnaces (4 2 i n i n di ameter at tuyeres 1 4 ft h i gh five 3 i n tuyeres) of .

, .
,
-
.

4 0 to ns ca p ac i t y ea c h for s i lv e r b ea r i n g a n d s i lver free anti moni al intermedi ari es ; - -

ei gh t oil fired di sti lling furnaces wi th retor ts holdi ng 1 30° i h ch arg e

-
s Fi gs 60 7 -
.
,
.

6 1 2 ; and tw o Rhodes cupell i ng f urnac es wi th tests holdi ng 5 tons ri ch l ead ,

Fi gs 657 664 — . The l ead bulli on fromr esi due reverberatori es N os 1 and 2
. .
,

Fi g 501 is tapped i nto po ts ta k en by a crane to the tw

.
, o li quati ng k et tl es and
, ,

stor ed On Saturdays the frozen lead bulli on i s li q uefied pur ifi ed by com

. pressed ,

ai r drossed p um
, ped i nto th e sof teni ng furnace and treated over Sunday as
, , , ,

bei ng har d i t req ui res m , or e ti me than the regular 2 4 hr gi ven to sof teni ng . .

I n addi ti on th ere is provi ded a sm all Patti nso n di vi si on wi th a dai ly cs

p ac i ty of 1 5 0 to n s le ad for co n v er t i n g p a r t of th e r efi n e d l e a d co n t a i n i n g t o ,

p er c e n t B i by a si ngl e c ry s t.a lli z at i o n ,

a n d th e H u l s t pr ess (p a g e 4 93 ) i n t o
corrodi ng lead wi th not over p e r c e n t B i I t co n t a i ns tw o cr y s talli z i n g . .

ket tles of 60 tons capaci ty four h eati ng ket tles of 2 0 tons capaci ty and one , ,

H ulst press .

The gases fromthe c upell i ng r esi d ue and blast f urnaces are drawn thro ugh , ,

a br i ck and steel flue by an 8 ft fan (Am eri can Blow er dri ven by a 35 h p
-
.
-
. .

mo tor and deli vered into a bag house of bri ck and steel 50 by 60 ft and 50 ft
, , . .

hi gh The bag ho use has fo ur bay s each wi th 1 44 woolen bags 1 8 in i n diam

.
, ,
.

eter and 30 ft lo ng . .

Steamfor th e sof teni ng and refini ng furnaces and for the air com pr essor i s ,
-

f urni shed by two H awkes boi lers ; elec tr i c p ower i s p urchased ; water i s deli vered
fromthe ci ty mai n to a g a l ta n k e l ev a te d 50 ft ; w a st e w a te r i-
s col l e c t e.d .

in a g a l s um p a n d r e
-
t u r n e d t o .th e el ev a t ed ta n k .

Th ere i s a ch ange house 35 by 85 ft wi th to i lets wash basi ns lockers and -

,
.
, ,
-

, ,

l unch room; and an office buildi ng and laboratory 36 by 1 2 8 ft ,

.

The lead b ulli on whi ch co m es m ai nly from the com pany s smel tery at ’
,

Tooele U tah contai ns Pb 99 5 p er c ent Ag 65 and Au

, , oz p er ton
. It is .
, . .

no t sam pled but deli vered di r ec t fromthe cars i nto the sof teni ng f urnaces by
,

means of a steamdri ven H owe conveyor Fi gs 504 and 505 O ther lead bulli on -

,
. .

i s unloaded i nto the tw o 4 5 ton k ettles m elted dro ssed sam pled and then
-

, , , ,

p umped i nto the sof teni ng f urnaces The dro ss i s cast i nto molds Fi gs 353 .
,
.

35 6 an d, sa m pl e d by m e a n s of a c i rc u l a r saw

2 38 Balbach . Sm elti ng and Refini ng Co , New ark , N J — T h i s pl a n t . . .

,

shown i n hor i zontal and v er ti cal lo ngi tudi nal sec ti ons i n Fi gs 0 a n d 0
5 3 i s
5 2 .
,

the latest h avi ng been er ec ted i n 1 9 1 5

, I t di fl ers radi cally from the o th er .

refineri es di scussed in that i t h as two levels i nstead of the usual thr ee and that ,

it m el ts i ts lead b ulli o n i n k et tl es i nstea d of i n r everber atory f urna c es .

The lead b ulli on i s m elted and dro ssed i n the p rem elt i ng k ettles and tr ans ,
5 10 M E TALL URGY OF LE AD

ferred by m eans of a centri f ugal p um p i nto a tro ugh deli veri ng into the sof teni ng
f urnaces on th e next level The sof tened bulli on i s pum . ped back by th e same
means to the desi lveriz i ng kettles and trea ted wi th zi nc The desi lveri zed , .

lead i s transferr ed by p um pi ng i nto one of the three r efini ng furnaces to be freed ,

fromthe zi nc i t r eta ins The refined lead goes to the si ngle r ecei vi ng reverbera
.

tory f urnace fromwh i ch i t i s m

,
olded di r ec t The lead fromth e upper refini ng .

furnac e flo w s i nto the r ec ei vi ng f urnace th at fromthe lower r efiner s i s p um p ed ,

i nto th e r ecei ver .

The hor i zo ntal sec ti on Fi g 502 sh ows at the ri gh t th e recei vi ng tr acks fo r

,
.
,

lead b ulli on and m ateri al s i n the c enter the desi lveri z i ng di vi si on and at th e
, ,

Fro .
50 2
—
. H oriz ontal secti o n Parkes p lant , Balbach S mlti ng
e and Refini ng Co .
,
N ewark ,

N .
J .

lef t the auxi li ary apparatus reverberatori es for dross and sk im , mi ng ( the blast
furnace is i n the sm el ti ng depar tm ent) the r etor ts for zi nc cr usts and c upels ,
-

for enri ched lead Far ther to the l ef t i s the par ti ng plant not shown
.
,
.

m
The l ead b ulli on arri v i ng on the rec ei v i ng track s i s unlo aded on to tr ucks
, , ,

sam ed and rai sed w

,
i th a traveli ng el ec tri c cr ane of 2 9 ft 7 i n span by tr uck -
.
-

loads of 50 bars and deli ver ed i nto the p rem

,
el ti ng k et tles The pi gs of lead .

bulli on on a truck are ti ed by a ch ai n and thi s connec ted wi th the book of the ,

crane .

The tw o pai r s of 6o ton coal fired k ettl es on the upper pl atformi ntended
-

,
-

for p remelti ng and desilveri zi ng are 1 0 ft 3 i n i n diameter and 3 ft 4 i n deep . . . . .

Under norm al co ndi ti o ns i a when the br i ck wall s and kettl es are hot i t tak e
,
. .
,
s ,
5 12 ME TALLURGY ’
OF LE AD

6 hr to melt a charge of 60 tons lead wi th a coal consum

. p ti on of 1 ton A .

mel ti ng kettle lasts for 2 2 8 charges ; a desi lveri zi ng kettle has to be replaced
af ter 1 50 charges h av e been tr eated .

Wh en the lead bulli on h as been m el ted the dross i s ski m med and freed ,

fromexcess lead by two H oward presses worki ng w i th a pressure of 1 00 lb .

p er sq i n T h
. e se a r e su
. sp en d ed fro m ji b c ra n es e a ch se r v i ng t w o k et t le s T h e , .

sq ueez ed dro ss i s dropped on to the floor the di scharges bei ng separated fro m ,

one ano ther by pi eces of scr ap sh eet i ron i n ord er to fac i l i tate th ei r r em oval
ped i n about 1 5 m
.

The drossed bulli on fromtw o kettl es i s p um i n i nto one of .

the softeni ng f ur nac es wh i ch holds 1 2 0 tons lead and has a h ear th 1 0 ft 1 0 i n

, , . .

by 2 2 ft and 1 ft 4 i n deep The sof tened bulli on i s pum

. . . ped i nto the two
.

60 ton desi lver i z i ng k ettles

-
These are work ed togeth er by three m . en w ho ,

desil veri ze th ei r ch arges i n 1 2 hr .

The desi lv eri zed lead i s nowp um ped i nto one of the three r efini ng furnaces
whi ch are of the same si ze as the two sof teni ng furnaces .

The recei vi ng furnace i s sm aller i n ar ea than the o th er r everb eratori es ; i t

has a hear th 9 by 1 7 ft 1 i n and 3 ft 7% i n deep and holds 1 00 to ns lea d . . . .

,
.

The retor t roo mi s w ell venti lated ; i t has at pr esent ei gh t oil fired retor ts -

( 1 2 00 lb ch
-
arg es ) i n .a ro w ea ch w i th i t s o w n .ch i m n ey ; ,
t w o r e t or ts h a v e a si ngl e

hood to carry 011 the fumes .

Si x c up el s wi th tests 6 ft 4 i n by 4 ft 5 i n and 6 i n deep hold i ng 6500

, . . . . .
,

lb lead have a soli d fo undati on The worki ng bo tto mconsi sts of a co urse of
.
,
.

magnesi te or chrome bri ck i n thi ck ; on top of thi s i s ram , med th e usual .

li mesto ne clay mix ture reachi ng to the working door ; above thi s the walls are
-

of fire bri ck -

The Co ttrell plant whi ch rec ei ve s the gases fro msi x c up elli ng and si l
,

ver fur naces i s i ntended to tr eat 4 ,

cu ft gas p er m i n I t has three com . . .

p a rt m e n ts ea ch w i th 3 0 s
,
tee l p i p e s 1 0 i n i n di a m et e r a nd 1 6 f t lo n g T h e ,
. . .

c urrent i s am p a t vol t s I
. t s work i s v ery sa t i sfa c tory ; n o f u m e s .

whatever are seen to ari se fro mthe stack .

2 39 Operati on, G eneral

. I n the flowsh eet Fi g 4 96 gi vi ng an outli ne .
-
-

,
.
,

of the Parkes process there are bro ugh t out the leadi ng steps necessary for desii
,

veri zati on These are recei vi ng l ead b ulli o n sof teni ng of lead b ulli o n de
.
, , ,

si lver i zi ng sof tened b ulli o n refini ng desi lv eri zed lead m oldi ng refined lead
, , ,

treatm ent of zi nc cr usts and treatm ent of i nter m ed i ary prod uc ts

,
E ach .

step r equi res cer tai n operati o ns all of whi ch dem and a detai l ed di sc ussi on ,
. .

24 0 Recei vi ng Lead Bulli on

.
— The lead b ulli o n usually arri ves at the t e .

finery i n car lo ads of fro m2 5 to 50 to ns In m o st i nstances the b ulli o n i s .

wei ghed and sampled at the refinery ; i n so m e work s th ese Oper ati o ns are carri ed

out at the sm el tery especi ally if both establ i sh m , ents b elo ng to th e sam e com

pany The necessi ty or om

. i ssi on of sam pli ng may govern the unloadi ng of a
car .

If the wei ghed and sam

b ulli on
pled at the refinery the recei vi ng
i s to be ,

track Fi g 4 9 7 i s lai d so low that the bo tto mof the car i s on a l evel wi th the
, .
,

m
“upper platfor ” of the works Along the whole leng th f h i pl f r
o t s at o m and .
,
 DE S ILVE RI ZA TI ON OF LE AD B ULLI ON 513

p a ar ll l
e r uns a narro wgaug
wi th th e rai lroad , m1 6 to 2 2 in gauge
-
e track of fro -
.
,

wh i ch b ears a number of strongly b ui lt low b ulli o n tr ucks They may be

.
-
.

buil t as foll ows A fram e co nsi sti ng of tw

. o pi eces of channel bar i ron 3 ft
,
-
.

lo ng i s fastened to the tw
,
o axles

o f t he wh eel s and steadi ed by tw ,

o

i ro n b ands runni ng di ago nally .

T he b ulli on i s carri ed out fro m

t h e car and loaded upon the
t r uck standi ng before the car
doo r ; wh en th i s i s filled to a
h ei gh t conveni ent for li f ti ng
( abo ut 316 i t i s m ov ed o n ,

a nd ano ther tak es i ts plac e The .

t rucks are run on scales placed at L — —‘ 68 D

o ne or tw o po i nts i n the b ulli o n

”
and scale sh ed the b ulli o n i s
-

wei gh ed and i s then sampled

,

wi th p unches fro m one tr uck

d i r ec tly up o n ano ther whi ch ,

t h en m oves strai gh t to the soften

i ng f ur naces or to p laces near
-

t h em and no m ,
ore handli ng i s
r equi red b efore the b ulli o n i s
ch arged i nto the furnaces The .

b ulli o n produced i n the smel ti ng

d epart m ent of the refinery i s
load ed at the blast furnaces or
r ev erberatory furnaces on to the ,

sam e ki nd of tr uck bro ugh t by an ,

“
el ev ator to th e bulli o n and scale
”
sh ed ,
and th en p asses to the

so f t eni ng fur naces .

At so m e work s the b ulli o n i s

unloaded and w ei gh ed as de
scri b ed and then tr ansferr ed to
,

a 4 5 or 6o ton k ettle m -
el ted i n ,

abo ut 6 hr when the k et tle i s

.

ho t and dro ssed ; di p sam

,
ples are
tak en f ro m the dro ssed bull i o n ,

and sawsam ples fro m the dross

-

whi ch has been cast i nto b ars

F
( gi . T h e m o l te n b u ll i o n i s th en s i pho ned ( g 5 )
F i 00 or p um p ed ( g
Fi . .

0
5 3 ) i nt o th e sof t e n i ng f u r n ac e A si m i l ar proc e d ur e
. i s fo und a t so m e

works whi ch transfer thei r blast or reverberatory f urnace b ulli on i n po ts to

the r ec ei vi ng ket tle When thi s i s filled and the lead been held at the correct
.
,

83
5 14 ME TALLURGY OF LE AD

te mp r
e atu e of r 370 to 380 perm °
C for sufi ci ent ti
i t the dross to ri se
. me t o
,

the latter i s rem oved freed fromadheri ng lead by 8 H oward press and the
,
.
,

b ulli on tr ansferred to th e sof tener .

Plants whi ch do not sam ple the b ulli on usuall y check the wei gh ts furni shed ,

by the smeltery and the railro ad by wei ghing car and bulli on on a track scale -

and t hen unl o ad th e car i nto the softeni ng furnace by m eans of the co nveyor

manufactured by the H owe Scale Co of Illi noi s Chi cago III Thi s chargi ng .
, , .

machi ne i ndi cated in Fi g 500 was first used at the Nati onal plant i n South
,
.
,

Chi cago 1
I t i s sh o w
.n i n si de and fro nt elevati o ns i n Fi gs 504 and 505 The . .

leadi ng parts are a steel struc t ure carri ed at th e lower end by a wheel tram ,

r unni ng on a track clo se to the railroad car and suspended froma si mi lar tram ,

at the upper The structure for m s the suppor t of a steel co nveyor dri ven by a
.

5 by 5 W ac h en gi ne T h e c ar br i ng i ng t h e b u
. lli o n arr i v e s o n a depr ess ed t r a ck ,

i s spot ted so as to bri ng i ts door approxi m ately i n li ne wi th the chargi ng doo r

of the sof teni ng furnace; the chargi ng machine i s moved so as to be i n li ne wi th

th e door s of the car and the sof tener i ts ti l ti ng roll er pl atformis lowered and , ,

the engi ne star ted Fo ur unl oaders i n the car pi ck the bars of b ulli o n fro m
.

thei r pi l es i n the car deposi t th emon the roll er table and push themo nto th e
, ,

roughened tables of th e co nveyor whi ch ca rri es themup the i ncli ne and deli vers , ,

themi nto an adj ustable ch ute down whi ch they gli de through the ch arging door ,

and land to w ard the c enter of the sof teni ng furnace I n order to prevent pi li ng .

up of bars i t i s i m portant that the furnace be hot at the start and contai n a
,

bath of lead whi ch shall m el t the bars as q ui ckly as they are ch arged The .

newcold charge wi ll i n ti m e cool the b ath of lead and the f ur nace to a sufi ci ent

degree for the dro ss to ri se and ca rry w i th i t m o st of the Cu contai ned i n the
bul li on In fro m2 % to 3 hr 2 500 and even more bars of lead bulli on are
. .
,

th us readi ly transf erred fro mthe railroad car i nto th e sof teni ng furnace .

In so m e plants wh ere the re is not sufli ci ent roo mfor a charging m

, achi ne ,

hand charging has been replaced in part by m

-
ech ani cal devi ces The lead .

bulli on i s pi led i n the car on a rec tangular frame of heavy plank placed near
th e door The loaded fram . es are r em oved one af ter ano ther by an elec tri c
truck transferred to a place beneath an overhead el ec tri c crane whi ch by m
, eans ,

of a chai n pi cks up the b ulli o n fro mthe fram

.
,
e and deli vers i t on to one or tw o

i ncli ned roller tables placed b efor e the chargi ng doors of the sof teni ng furnace .

Fro ma table tw o m en d epo si t on to the roll ers the i s whi ch gli de i nto the
pg ,

f urnace They handle 40 tons in an ho ur

. .

24 1 Softeni ng Lead Bulli on The obj ec t of softeni ng i s to separate fro m

.
— .

th e lead bulli on prod uced i n the blast fur nace i m p uri ti es such as a Cu S Sn , , , , ,

As Sb etc th at wo uld i nterfer e wi th the desi lveri zati o n I t co m

, ,
. pri ses two .

processes li quati o n and o xi dati o n By the form

,
er m etals and th ei r co m po unds .
,

held i n soluti on by the red hot blast furnace lead are sep arated agai n fro mthe -

rea di ly fusi ble lead by mel ti ng i t slowly at a low tem p e r a t u r e B y t he la t ter .

,

metals alloyed wi th th e lead and more easi ly oxi di z ed than the lead are removed , ,

by heati ng i t to a bri gh t red wi th access to air, wi th the resul t that these m

-
etals
1 Pulsi fer, Mi n. E ng . World, 1 9 1 3, m m 54 , 1 .
516 ME TALLURGY '
OF LE AD
TAB LE 1 22 .
— ASSAYS or LE AD Bou ron AND E nsu w
c Dnoss

In Table 121 fro mClausthal and Lautenthal demonstrate that

the analyses
th e charac ter of a co m parati vely p ure lead i s i m proved by mel ti ng slo wly i n a
kettle and th en drossi ng By co mpar i ng the two Frei berg analyses the degree
.
,

to whi ch the forei gn m atter of a v ery i m pure lead b ulli on m ay be rem oved
wi ll be seen; vi z nearly all the S 96 per cent Cu 99 p er cent N i and Co 2 5
.
, ,
.
, .
,

p er c ent A s
. a,
n d o nl y p er c ent S b an d p er cen t A .
g; B i ,r emai ne d .

entirely i n the l i q uated lead and all the Sn exc ep ti ng , p er c en t Th e se .

data find thei r explanati o ns i n the freezi ng poi nt c urves I t must be remembered -
.
,

however that dro ss always retai ns entangled par ti cles of lead b ulli on
,

el ti ng t he dro ss fro mFr ei b erg i n a cr uc i ble Schertel Ob tai ned i n well

.

On m 1
.
,

sep arated lay ers the three prod uc ts l ead sp ei ss and m

, atte g i v en i n T ab le 1 23
, , , .

TAB LE 1 23 .
—ANALYSES or PRODU CTS 1 11 011 ME LTI N G Dnoss

1
B erg H iltten
. mZ. .
, 1 88 2 , x m 93
, 2 .
 B E S ILVE RI ZA TI ON OF LE AD B ULLI ON 517

The absence of Fe i n ei th er p matte proves that these i mp uri ti es do s ei ss or

not resul t fro mfinely di vi ded blast f urnace spei ss or m atte di ssolved i n the

lea d as has been often tho ugh t I t tends to show that bei ng held i n soluti on
, .
,

or suspensi on the i mpuri ti es uni te on li quati ng to formco mpounds that are not
, , , .

fusi ble at the tem perature at whi ch the lead was m el ted and that th e concen ,

trati on of Cu i n dro ss i s due p rob ably to the pr esence of S and As and not to
the sep arati on of an all oy of Pb and Cu .

Tabl e 1 2 2 show s that the Au content of the dross ri ses w i th that of the Cu -
.

Thi s finds i ts explanati on i n the fac t that Au and Cu for m soli d sol uti o ns ,

thro ugho ut 1
.

In m el ti ng lead b ul li on that i s v ery ri ch i n Cu the am ount of dross for m ed i s ,

sure to be larg e As i t carri es wi th i t preci ous m

. etal beari ng Pb i t wi ll r ed uc e - -

the di rec t yi eld fro mthe charge b elow a prac ti cal li m it In or der to prevent .

thi s at so m
, e works galena i s added to the sof teni ng f urnac e ch arg e for the p ur -

pose oi for mi ng a m at te wi th the Cu co ntai ned i n the l ead b ulli on The resul t .

i s that all the Au r em ai ns i n the m etal bath and only a sm all p ercentage of Ag i s

carri ed ofl by the matte .

H eberlei n fo und that To readi ly entered the dross and di d not follow the
2

As and Sb i nto the ski m ming as one mi gh t be led to expect fromthe si milari ty
between i t and these metals Thi s may be at tri buted to the chem i cal com
.

m
m
°
p o und P b T e wh i ch fr eez es at 9 7
1 C 1
or a n d ay b e assi ste d by the .

presence of Cu whi ch for s the compounds Cu1Tes and CugTe freezi ng at ,

°
62 0 and 8 56 C .
1

At Pertulosa, I taly , i n refini ng lead b ulli o n wi th 5 p e r cent . Te, the

lead produc ts co ntai ned the a o unts of Te shown i n Table 1 2 4 m .

TAB LE 1 24 — TE LLU E n
. mCONTE NTS or RE rrNE nx PRODU CTS

Products

Sof teni ng dross

Softeni ng ski i ng mm
Softened lead bull i on 0 .
5 2 2

Sof tened bulli on ( f ter first z i n

ack i ng)
Sof tened bulli on ( after second z i ncki ng) .

Market lead ( after thi rd zi ncki ng and

refini ng )
Refini ng ski mmi ng

Roberts Austen and-

Ki rke Rose, Proc Roy S oc ,
-
. . . 1 90 1 , v n, 1 05 .

KurnakowSche tschusch ny, Zt ouarg Chem, 1 907, U V, 1 64

-
m . . . .

1
B erg H uttenm Z , 1 89 5, LN , 4 1 ; M i n I nd , 1 89 5, IV, 4 80
. . . . . .

1
Fay Gi llson, Tr A I M E , 1 90 1 , xxxr, 5 2 7
- .

mI nd
. . . . .

Ki m ura, M em Coll S ci ence, I m p. U ni v K o t

y , 9 5, ,
o 1. 1 I 4 1 9; . . J . S oc Che
. . .
,
1 9 1 5,
v, 1 2 1 1
xxx r

m
.

1
Chik as hi ge, Zt . anorg . Che .
,
1 9 7,
0 LIV, 54 .
5 18 ME TALL URGY OF LE AD

If a. sa mpl fro mthe lead af ter drossi ng be po ured i nto a small

e, taken ,

mold and allowed to cool slowly a crystalli ne bri gh t pewter whi te spo t will
, , , ,
-

appear on the sli gh tly depressed dull grayi sh whi te surfac e whi ch i n addi , ,
-

, ,

ti on to the hardness of the lead i s charac teri sti c for the p resenc e of As and Sb ,
.

If af ter drossi ng the tem

,
perature of the lead bath i s rai sed to a good red
,

heat and ai r freely adm i t ted the three leadi ng i m puri ti es co ntai ned i n the
,

lead wi ll oxi diz e i n the following order: first Sn then As and lastly Sb; at the , ,

sam e ti m e so m e Pb w i ll be conver ted i nto PbO The surfac e at first wi ll beco m e .

q ui ckly covered wi th dark yell ow ski mm i ng whi ch vari es fro mpowdery to ,

pasty but i s not fused on acco unt of the refrac tory nature of SnO and SnOg
, ,
.

It form s the so call ed tin sk i m -

mi ng whi ch consi sts mainl y of anti moni ate and ,

stannate of lead and anti m o ni ate of ti n and i s worked by i tsel f ,

As soon as th e ti n ski m mi ng has been drawn fromthe surface of the lead ,

thi s b egi ns to gi ve 06 f um es of arseni c and anti m

m
o ny and arseni ate and anti ,

moni ate of lead begi n to form A sam e of thi s fume gave Iles : As .

Sb Pb p er ce n t A g a nd A u o z .
p, er to n Th e a r se n i a t e . .

of lead i s lemon yellow to li gh t brown the anti moni a te dark brown to black ;
-

bo th are fused and drawn 03 together as anti mony ski m ming after the
f urnace has been sufi ci ently cooled to cause i t to soli di fy Toward the .

end of the operati o n the anti m ony oxi de i n the ski mm i ng will be replaced by
lead oxi de unti l the black color has changed to the greeni sh yellow of li tharge .

Sam ples are then tak en to see how far the softeni ng has p rogressed Befo re .

the Sb has been rem oved a sam ple of the bulli on taken i n a ladle will
,

i e sm all p ar ti cles of m el ted black ski m mi ng wi ll float on the surface

“
wor . .
,

of the lead wi th a ro tary m

,
o ti on whi ch resembles that of parti cles of dark
g r ea se on ho t w a t er A s th e s of te ni ng. a ppro a ch es th e fi n i sh i ng po i n t th e ,

glob ules beco m e less i n num ber and sm aller i n si ze a thi n coati ng of yellow ,

li tharge forms m ore readily on the red hot lead and finally no more glob ules -

are seen and li tharge for m s q ui ckly .

When a sample of sof tened lead bulli on i s poured i nto a m old allowed to ,

cool slowly and ski mmed wi th a flat pi ece of wood i t wi ll when i t has been
, , ,

soli di fied h av e lo st the ch arac teri sti cs of As and Sb and the surface of the bar
, ,

wi ll have assumed a ri ch i ndi go blue color The lead has beco me so soft that i t -
.

can be easi ly scr atched wi th the fing er nai l ; and i nci si o n m ade i nto a bar wi ll

show a bri gh t m etalli c luster ; c upelli ng a sam p l e w i ll f ur ni sh a c up e l su rf a c e

free fro mi ncr ustati ons .

2 4 2 Softeni ng Furnace
.
— The f ur nace used al m o st excl usi vely i n the Uni ted
States i s the reverb eratory ; i t serves for the operati o ns of li quati ng and oxi di zi ng
f usi ons Formerly sof teni ng furnaces were b ui l t large eno ugh to hold fro m8
.

to 1 0 p er c ent m ore lead b ulli on than the kettle i nto whi ch they di scharged
.

th ei r contents The k ettl es used to hold 30 tons sof tened and the reverb eratori es
.

4 0 to ns cr ud e b ulli o n A s t h e t i m e re q ui r.e d for so f t e n i ng a l a rg e ch a rg e i n a

sui table f ur nace i s not lo nger than a sm all one but m ore eco no m i cal i n labo r , ,

fuel and repai rs the tendency has been to i ncrease the si zes of furnaces and
, , ,

di scharge thei r contents into several k ettles The d esi lverizi ng k ettl es have .
520 ME TALLURGY OF LEAD

The bri ckwork of the hearth i s readi ly attacked by the anti m ony ski m ming
and li tharge formed i n the oxi di zi ng f usi on In order to counterac t th e cor .

rosi o n and 3 i n w ater pi pe w

,
as placed nex t to the p an at the lev el of the
-
.
-

lead li ne The bri ckwork was eaten away to a th i ckness of from2 to 3 in

-
. .

FI G 08 — El vati on of flue end FI G — Verti cal secti on on li ne —

C D
.
5 . e . .
509 . .

as q ui cklyas wi thout the pi pe but then the corrosion proceeded only very ,

slowly and the li fe w

, as th us greatly prolonged The use of water pi p e i s not .
-

uncom mon i n cupelli ng furnaces In 1 873 E Balbach Jr enclosed the p an

1
. . .
,

holdi ng the hear th wi th ano ther leavi ng a water space of 3 or 4 i n between ,

-
.

FI G .
51 0
— V —
erti cal secti on on li ne E F .

the t wo cooled not only the si des but also the bo tto m Whi le thi s
,
and thus ,
.

mode of cooli ng i s very eflecti ve there i s too much of i t consi der i ng the fuel , ,

requi r ed to mai ntai n the temperatur e necessary to sof ten the lead i n a given
ti me I t does check the corrosi o n of the h ear th bo tto mby w
. h atev er li tharge

FIGS and —D etail of tap

.
5 1 1 5 2
1 . .

remains i n the furnace after the lead bulli on or i n the r efini ng furnace the ,

refined lead has been tapped and i s not floated up agai n by the next charge
, , .

Ai r cooli ng has always been fo und suffi ci ent for th e bo t tom

-

; w ater cooli ng is -

1
U S Patent , No
. . . 1 41 91 2, Aug . 1 9, 1 8 73 .
 DE S I LVE RI ZA TI ON or LE AD B ULLI ON 52 1

s sary
nece for si
des only ; all softeni ng and refini ng f urnaces are provi ded
the
wi th soft steel j ackets on si des and ends
-
.

In order to i ncrease the li fe of the bri ckwork the fire bri ck have been t e ,
-

placed especi ally along the lead li ne by m

, agnesi te and chrom e br i ck
1
, .

The m anner of p utt i ng i n the h ear th var i es som ew hat A layer of brasq ue .

i s tam ped i n and then cut out so that the co urse of fire bri ck lai d endwi se shall -

, ,

bri ng i t to the desi red shape and gi ve i t the necessary i ncli nati on toward the
tap hole (Fi g
-
In m
. any f ur nac es only the c entral par t of th e i nv er ted

arch i s th us carri ed by brasq ue and the r em ai ni ng sp ace i s bri ck ed up ( Fi gs .

5 32 a nd In p ut ti ng dow n t he bo t to m th e br i cks h av e to b e jo i ned as ,

ti gh tly as possi ble For thi s purpo se they m

. ust fir st be caref t sel ec ted and

fi tted by r ubbi ng together unti l all ro ughness i s r em oved E ach bri ck i s .

di pp ed i nto water and th en i nto a clay m or tar h avi ng the consi stency of very
thi n gr uel ; i t i s th en p ut in p lace and dri ven wi th a h am mer agai nst the bri ck
i t i s to face Thi s m . akes the joi nt as close as possi ble and pr events the p assage

of lead The si des of the furnace are bui l t wi th the same car e as the bo ttom
. .

Com monly they rest on the curved worki ng bo ttomto prevent thi s fromri si ng .

The roof i s suppor ted on ei th er si de by sk ewback s and the f ur nac e bo und ,

wi th buckstays and ti e rods The manner of tapp i ng the furnace deserves-

.

speci al m enti on The tap hole i s an openi ng 2 to 3 i n i n di am

.
-
eter and usually ,
.

coni cal, i n a cast i ron plate whi ch someti mes i s water cooled The hole i s
-

,
-
.

closed by means of a clay plug rammed i n firmly In order to m ak e break i ng

m
.

away i m ssi ble the clay pl ug i s r ei nforc ed by an i ro n pl ug h eld i n pl ac e by

,

an i ron wedge dri ven between i t and a horiz ontal pi ece of flat i ron k ep t in -

posi ti on by the ver ti cal buck stays of th e lead spo ut -

.

Th e f uel com monl y used for firi ng i s bi tumi nous coal (Fi gs 506 .

in m any work s thi s has b een r eplaced by oil ( Fi gs 5 3

1 i n o ne pla nt .

provi si on i s made for bo th coal and oil firi ng (Fi gs 51 7 W i th a good -

.

grade of bi tum i nous coal nat ural draf t i s suffi ci ent to soften the lead bulli on i n
,

th e r eq ui r ed ti m e Wi th slack coal undergrate blast becomes necessary The

.
, .

adm i ssi on of ai r under pr essur e through a ser i es of sm all pi p es i n the roof i s

sati sfac tory w i th coal r unni ng hi gh i n volati l e m at ter In usi ng oil the .
,

pressur e air servi ng as atomizer furnishes all the O necessary for oxi di zi ng
-

the i m pur i ti es to be scorifi ed .

2 43 Meth od of W orki ng
.
— The m ode of Operati ng the soften furnace i s
regulated i n such a manner that the ti me req ui red for chargi ng sof teni ng and , ,

tap pi ng shall not exceed 2 4 hr There i s no di fli culty i n do i ng thi s w . i th

bulli on contai ni ng abo ut 1 p er cent i mpuri ty The ai mi s to make up the . .

charges i n such a way that they shall not exceed thi s amount .

The b ulli on is charged by h and or m echani cally ; som e or ev en all of i t m ay

be p um ped i n In hand chargi ng paddles are used to place the bulli on

.
-

,
.

The paddl e i s a r ec tangular i ron bar about 8 ft long m ade of 1 % i n i ron .

,
-
.
,

one end bei ng flattened out for a di stanc e of 2 ft 6 i n to the w i d th of 3 i n . . .

,

to r ecei ve a bar of b ulli on ; the o th er i s rounded 05 and bent to a r i ng .

1
H avard E ng M i n J 1 908 m
,
. oo cw 80 2 . .
, , , .
ME TALLURGY OF LEAD
524 ME TALL URGY OF LE AD
 DE S ILVE RI ZA TI ON OF LE AD B ULLI ON 525

A lug i s often cast on ei ther si de of th e door frame to suppor t a roller I t -

.

serves as b ear i ng for the paddle i nstead of the door fram e and th us f aci li tates -

the m ani p ulati on Chargi ng by m

. ach i nery h as been di sc ussed i n § 2 2 9 .

The work of the Mi ll er centri fugal pum p i s ta k e n up i n F i g s 6

5 3 5 66 . .

I t i s com mon prac ti ce i n our days to dross very carefully the blast f urnace
b ulli on i n a kettle befor e casti ng i t i nto bar s whi ch are to go to a r efinery Thi s .

explai ns the pr evalence of hasteni ng the m el ti ng of th e b ulli on i n the sof tener ,

wh i ch would be absolutely wrong wi th undrossed m ateri al Af ter the bulli on .

has been m el ted i t i s sti rr ed to detach som

,
e of the lead h eld i n suspensi on by

the dross ; so m eti m es fine coal i s spr ead over i t and sti rred i n Thi s i s very .

eflecti ve wh en the bulli on i s p ure so tha t li t tl e dross ri ses to the surfac e , Wi th .

im pure bulli on consi derable fuel i s requi red to have any efi ect and ther e i s ,

danger of the temperatur e becom i ng too hi gh and th e lead taki ng up agai n ,

som e of the i m puri ti es that had separated Th e dross i s removed by a rabble .

or a rec tangular ski m mer .

Th e head of th e rabble i s m ade of i n i ron and i s 3 by 1 2 i n the handle -

.
,
.
,

of i n i ron and 1 0 + ft long

-
.
, The handle of the ski m
. . mer i s of the same
leng th and thi ckness as that of the paddle; the perforated par t i s m ade of M i n -
.

i ron and i s 1 0 by 1 2 i n the perforati ons bei ng 95 i n i n di am

,
.
,
eter . .

Wi th ei th er tool abo ut the sam e am o unt of lead i s wi thdrawn wi th the dross

fromthe furnace so there i s li ttle choi ce b etween them; some prefer one some
, ,

the o ther Th e h andle of ten rests i n a hook suspended by a chai n fro mth e
.

roof th us facili ta ti ng the work The operator removes fromone si de the dross
,
.
,

whi ch hi s helper on the o ther si de collects wi th a rabble pushi ng i t toward the ,

door or upon the ski m mer The dross whi le bei ng removed fromthe furnace
.
, ,

i s coll ec ted i n a sli gh tly coni cal cast i ron m old runni ng on wheels e g 2 by-

,
. .
,

3 f t a t th e b as e a n d 1 4 i n d eep m ad e of ln i ro n or i n a sla g p o t w i th t a p
hole or i n an i ron two wh eel barrow w
- -
.
, ,
. .

,
-
i th p erforated bo ttom i n or der that som e ,

of the lead carri ed out wi th the dross may run 06 on the cas t i ron plate i n front -

of the ski m mi ng doors and be returned to the furnace Th e use of galena

-
.

wi t h bulli on r i ch i n COp per has already been referred to above .

Th e dross drawn 06 i s wei ghed and a sam ple i s tak en fromthe lead rem
, ai n

i ng i n the furna ce to be assayed The wei gh t and assay val ue of the b ulli on
.
-

charged bei ng k nown the wei gh t of the dross and the assay of the resi dual
,

hard lead gi ve the data necessary to calculate the to tal si lver contai ned i n the
dross and wi th i t i ts assay The amo unt of dross formed v ari es ; i t i s about 3
,
.

p e r c en t of t
. he b u lli o n c h arg ed an d a ssays abo ut 80 p er cent Pb
, I t i s fr ee d . .

fromsome of i ts lead in a li quati ng furnace and wi ll then have a composi ti on ,

shown i n Table 1 2 2 .

The ti n sk i m mi ng that forms on rai sing the temperatur e after drossi ng

i s r em oved i n the same way as the dross .

Mo st lead bulli on conta i ns so li t tle arseni c th at arseni c sk im mi ng i s not

kept separate fromthe si mi lar anti m ony ski mmi ng If th ere i s enough arseni c .

p re se n t to w a rr an t k e ep i n g th e tw o sk i m m i n g s se p ar ate th e a rsen i c s k i m m i ng ,

is taken and handled as i s the anti m o ny ski m mi ng .

526 M E TALLURGY ’
OF LEAD

Wi th the anti m ony ski m mi ng i t i s custo mary to cool the furnace by throwi ng
open the doors i n order that th e anti moni ate of lead floati ng on the surface
,

may harden and be then taken 06 in the formof a thi n crust by means of a
,

hoe and a paddle In wi thdr awi ng th e ski m

. mi ng i t is advisable to leave in ,

the furnace th at par t wh i ch adh er es to the bri ckwork The sk i m mi ng eats .

i nto the bri ckwork for a shor t di stance and then soaks m ore or less i nto the
r em ai nder
. A cr ust of ski m mi ng adheri ng to the soaked bri cks pro tects
themfromf ur ther at tack .

If the bulli on i s very h ard ski m mi ng once wi ll not be sufi ci ent to soft en i t
,
.

The furnace i s th erefore agai n h eated up ; and as soon as th e surfac e of th e lead

i s well covered cooling and sk i m
,
mi ng are repeated Ordi nari ly two operati ons .

are sufli ci ent but so m ,

eti m es three are necessary To hasten the cooli ng of .

the fur nace slak ed li m

, e i s so m eti m es spread over the m etal b ath So m e re .

fi ners add li m e to the f ur nace af ter drossi ng wi th the i d ea th at an anti m oni a te ,

of li m e i s form ed and th us less lead i s oxi di z ed duri ng the sof teni ng

, Thi s .

efl ect of li m e still r em ai ns to be proved Any addi ti on of li m e to the f urnace

.

has the great di sadvantage of i nterf eri ng wi th the subsequent treatm ent of

the anti m ony skimm i ng and i s therefore better di spensed w

, i th al togeth er .

W i th bulli on ri ch i n Sb i t is of ten not possi ble to fini sh the work of th e

furnace in 2 4 hr An addi ti on of refini ng ski m
. mi ng 5 1 and 2 5 )
2 or l ea d
oxi de fromthe moldi ng apparatus greatly assi sts the oxi dati on of Sb Ordi nari ly .

i t i s not advi sable to use li th arge fromthe c up elli ng f ur nace as th is i s li k ely t o ,

contai n Cu whi ch would enter the bulli on and afl ect desi lveri zati on in the k ettle .

Of cour se li th arge free fromCu is pr eferable to other lead oxi des as i ts Ag i s

, ,

taken up by the b ull i on An addi ti o n of from1 0 to 1 5 tons lead oxi de to 2 50

.

to ns drossed lead b ulli on is a com mon amount The finer the oxi de the more .
,

q ui ck wi ll be i ts ac ti on .

Steamhas been used to sti r up the lea d and th us expo se fresh surfaces to
the oxi diz i ng ac ti o n of th e ai r Thi s i s do ne by i ntroduci ng through the
.

chargi ng doors a 1 i n p i pe to the end of whi ch are scr ewed by m

-
.
, eans of a T , ,

tw o p i p es havi ng a num ber of perforati ons on ei ther si de and closed at the ends .

The m ai n pi pe i s bent so that i t i s i ntrod uced i nto th e f ur nace and held i n

place by the closed f ur nace door whi ch has been wei gh ted ; the two pi pes
-

at i ts ends wi ll be pressed down i nto the l ead and run parallel to the side s of ,

th e f ur nace Tho ugh the i ntro duc ti on of steamdoes shor ten the ti m
. e req ui red

for sof teni ng i t has the di sadvantage that i t forms a large am

, ount of ski m mi ng ,

and th at the swash of th e l ead oxi d e and anti m oni ate strongly corrodes the si des
of t he f urnace It has th erefore not found much favor
‘

. .
, ,

Ano th er m ethod to be m enti oned i s th e one in use at Fr ei berg where bull i on ,

ri ch in ti n arseni c and anti mony is sof tened Blast i s i ntroduced on ei ther

, , .

si de of the firebri dge ; th e sk i m mi ngs are removed at th e flue end of the

f urnace as fast as they form The tool used i s a long i ron hook to whi ch is
.
,

fastened a triang ularpi ece of wood say 8 i n lo ng W i th i t the ski m mi ngs are
, . .

drawn out of the f urnace i n a th i n stream I n order to faci li tate the work and .
,

to enabl e the w ork m en to pass gently ov er the surf ace, and th us r em ove only
528 ME TALLURGY ’
OF LE AD

TABLE 1 2 5 —.AS S A Y S or ANTIn ONv a nnN os

11
I ncludes 1 to 2 p er cent . meta lli cs .

(1) A nn . Mi n . Belg .
, 1 901 . VI , 2 55 . ( 2) Tr A ustralas
. . I nst . Mi n . E ng , . 1 9 07 . x 11 . 2 1 .
( 3) Op . ci t . ,

1 89 8. V, 2 2 8.

TAB LE 1 26 — AN ALYSE S
. or FLUE -
DU S T 1 11011 SO TTE N I NO FU RN ACES

244 Desilveri zati on of Softened Lead Bulli on, General

.
— Fro the soften m
°
i ng f ur nace the l ead , when cooled to a vi si ble red, or about 500 C , i s tapped .

i nto the desi lver iz i ng

kettle b whi te washed wi th li me water and , whi ch has een -

heated to the poi nt where a spl i nter of dry wood thrown on the bo ttomwi ll
i gni te r eadi ly w
°
h i ch corresponds to abo ut 400 C The whi te wash i ng faci li tates
,
.
-

the rem oval of si lver cr usts wh i ch adh ere to the si des wh en the k et tle i s cooli ng .

If the l ead wer e tap ped i nto a cold k ettle thi s wo uld be li k ely to crack on th e ,

bot tom and the ti me for bri ngi ng the lead up to the requi red temperatur e
,

wo uld be unnecessar i ly prolonged The lead r uns i nto a trough of cast i ron .
,

i n thi ck or a ch annel i ron or an I beam placed beneath the di sch arge

.
,
-

spo ut of the f urnace In order to decrease the am ount of dross the lead r uns
.
,

fromthe trough through a cast i ron pi pe wh i ch co nduc ts i t to the si de of the -

kettl e .

The k et tle dross form ed am o unts to about 1 p er cent of the bulli on charged
-
. .

I t i s ski m med 03 and added to the next charge i n the softeni ng furnace af ter
the furnace dross has been tak en 06
-
The k ettle i s nowr eady for the addi ti on .

of zi nc .

The quanti ty of zinc necessary vari es wi th the p uri ty of the lead and in
cr eases on the whole wi th the am ount of Ag present Pr esuppo sing the lead .

°
to be pr ac ti cally p ure i t w i ll tak e and hold i n sol uti on at abo ut 4 00 C
,
.

between and av er age p er c ent Zn Thi s am o u nt h as to be add ed . .

to the k et tle befor e the lead wi ll gi v e up any of i ts Ag; i t i s th er efor e a constant .

The q uanti ty of z inc req ui red to com bine wi th Ag must be based on th at needed
to formAga s Plattner showed byexp eri m
1
. ents on a work i ng scale how ,

the zi nc r eq ui red i ncreased wi th the Ag content H is data are gi ven i n Table -

.

1 27 .

1
Berg H utten . mZ. .
, 1 889, x wm 1 1 7 , .
 DE S I LVERI ZA TI ON OF LE AD B ULLI ON 529

TAB LE 1 27 — ZINC RE Q UI RED

. Iron DE S I LVE RIzATION W I TH I N CRE AS ING AG—CO NTE NT or LE AD
Ag in lead bulli on, oz .
per ton Per cent . of zi nc added

Roswag formulated the am

1
ounts of zi nc req ui r ed Z
i n whi ch Z th e zi nc p er 2 000 lb lead and A assay Ag oz per ton . H e also ,
. .

expr essed alg ebrai cally the q uanti ti es of zi nc fo und by Ill i ng to be necessary
1

i n desi lveri zati on : Z the lett ers h avi ng the sam e m eani ngs

as abov e Th ese general form

. ula: probably gi ve an appro xi m ate i dea of th e

to tal am o unts r equi red to desi lveri ze lead bulli on r unni ng low i n Ag say 30 to ,

5 0 o z .
p er to n ; for r i ch b u ll i o n th e y a re to o h i gh .

I n prac ti ce i t h as been fo und to be i m po ssi ble to desi lverize hi gh grade lead -

bulli on by a single ad di ti on of zi nc ; th e ri ch er the bulli on the less difl erence i s

there between the assay values of the zi nc si lv er cr ust and the resi dual lead -
.

Form erly i t w as custom ary to have thr ee and ev en fo ur zi nck i ngs At present .

i t i s uni formpracti ce i n the Uni ted Sta tes to desi lveri ze by m eans of tw o addi

ti ons of zinc provi ded th at no gold cr ust i s m ade Thi s m ode of operati ng m ay .

r equi re more zi nc than the one th at prevai led formerly but i t i s a deci dedly ,

cheaper method The ai mi s to concentrate as much Ag (and all the Au) as

.

p o ss i bl e i nt o t h e fir st th e sat u r a t ed
,
c ru st a n d th er e by u ti l i ze all th e d e , ,

si lv eri zi ng power of the zi nc Thi s crust assay i ng ov er 2 000 oz Ag p er ton

.
,
.
,

goes to the r etor ts In the second and final zi ncki ng an excess of zi nc over
.
, ,

th at whi ch i s r eq ui r ed to com bine wi th the Ag i s used ; thi s i s neces sary i f the

Ag i s to be r em oved com pletely from the lea d The resul ti ng unsaturated .

crust has sti ll some desi lveri z i ng power ; i t i s therefore co llec ted in m olds and
used to take the place of part of the fr esh zinc r equi r ed i n the first zi ncki ng It .

i s assum ed th at tw o th i rds of i ts zi nc content i s avai lable as newzi nc

-
The .

second crust assays from1 0 to 30 oz Ag p er ton . .

The anal yses of Table 1 2 8 show the co m po si ti ons of some zi nc si lver -

cr usts ob tai ned fro m low grade b ulli on whi ch has been dro ssed o nly and -

retai ns the Sb and of li q uat ed zi nc si lver ( gold) crusts fro msof tened b ulli on
,
-

ri ch i n Ag and Au Of the zi nc si l ver gold cr usts t he one analyzed by Jenk s

.
- -

( )
It s how s an ab n or m al co m po si ti o n as th e r et or t b u l li on assays or di nari ly ,

2 000 oz Ag and 5 or 6 oz Au p er ton

. Thi s cr ust resul ted fro mb ulli o n
. .

co ntai ni ng as i mp uri ti es Cu As and Sb p er c en t I t .

l ook ed li ke sm all spo nges of brass floati ng i n the nor m al gold crust .

They for m ed to the am o unt of several hundred po unds .

All the Germ an si lver cr usts gi v en run m uch lower i n si lver than any
fro mAmeri can refineri es Tho se fro mAl tenau and Lautenthal retai n m . ore
l ead than any of the o ther s as they are to be m el ted agai n i n a k ettl e
,

and deco m posed by steam whi ch co uld not be sati sfactori ly done if the ,

li q uati o n had been carri ed any fur ther .

1 “La désar enta ti on dc lomb,

”
D unod Pari s,
g p , 1 884 , p . 241 .

1
Z t B erg B atten S al
. . . . W i . . Pr , . 1 868, x vr, 5 1 .

34
ME TALLURGY OF LE AD

0 O O
5 n n

0 0
0
0 0
0 3
8 8
.

9 9

0
0
8
k
.

.
. .

. . .

5
O O O O
a
mwh
.

A v m
mO fi
. .

o n e z

4 Z h a
N
532 ME TALLURGY OF LE AD

E xa mple —
A Thi s
plant desil veri zes i n 80 ton kettles A kettle recei v es -
.

65 tons sof tened b ulli on to be desi lveri zed by 3 5 tons seco nd cr ust (from a
,

prec edi ng ch arge i n the formof ski mblocks) and th e r eq ui red newzi nc .

I n Table 1 30 are gi ven the necessary po unds of new z i nc to be ad de d

m
.

Th e ket tle i s ski m med hot ( 51 5 th en are taken the h ot sam e (gu
°

drop ) and th e cold sam ple for assayi ng The hot sam ple i s poured i n t o
.

a cold coni cal m old as soon as taken from the kettle; the cold sample i s
ob tai ned by allowi ng the hot ladle content to cool i n the ladle unti l a ll
-

the cr ust h as ri sen to th e surface and the lead under neath shows a clea n
,

lustro us bluish surface when the floati ng cr ust has been p ushed asi de and ,

then pouri ng the l ead near i ts fr eez i ng tem perature i nto a si mi lar cold mold .

The hot and cold sam ples are assayed for Ag and the amo unts of newz i n c
to be added tak en fromTable 1 3 1 The k et tl e i s cooled only after the seco nd
.

zi nck i ng wh en th e desil veri zed l ead i n the k ettl e o ugh t to co ntai n no t over
,

Ag p er ton .

EXAMP LE A

TAB LE 1 30 — FI RS T ZI NC
.

80 ton kettle:
-
( 5
6 t ons of lead bulli on ; 3 5 tons Ski mbl ocks ro f mp revi ous charge and newzi nc)
SorrE NI N G -
TU RN ACE CH ARGE
Assay: oz . Ag ( Au) per ton Pounds newz i nc to be added

E xa m ple B —plant has

Th i s
.
—
60 ton k ettl es
whi ch however rec ei ve 62 tons , ,

lead bulli on The zi nc schedules gi ven i n Tables 1 3 2 and 1 33 are based on

.
, ,

th i s amo unt The crust of the first zi ncking is pressed hot ; that of the second
.
,

cold The cr ust of the second zi ncki ng i s added to the next followi ng ket tle
.

charge to replace par t of the fresh zi nc needed I n order to determi ne how .

much fresh zi nc the second crust is likely to replace a cold sample is taken ,

from the ket tle whi ch furni sh ed the cr ust af ter the gr eater par t of the Ag
had been r em oved by the first zi ncki ng and assayed Th i s exp lai ns the ,
.

cap ti ons 1 0 1 5 1 8
, , , 60 70 i n Tabl e 1 3 2 , .
 DESILVERI ZA TI ON OF LEAD B ULLI ON

EX AI PLE A

TABLE 1 31 —
. SE COND ZINC ( So -
ton k et tle)

H ot -
mpl
sa e (gumdrop ) assay

Oz Ag per ton
.

Pounds zi nc to be ad ded
1 500 1 550

1 52 5 1 5 75

1 550 1 600
1 5 75 1 62 5
1 600 1 650
If over 1 1 0 oz per ton, take 06
. f
another p ress a ter first

sk im, pres s hot ( 9 60

°
F . cool down onl y
f
a ter second z i ncki ng .

Ex n rp LE B

—
TAB LE 1 32 . FIRST ZI NC ( 6 2 ton kettle)
-

added
534 ME TALLURGY OF LEAD

EXAMP LE B

T AB LE 1 33
.
— SE COND ZI NC ( 6 2 ton kettle)
-

added added

Exa ple m —
C Th i splant has 60 and 1 00 ton desi lverizing ket tles and -

works i n the sam e m anner as do p lants A and B In Table 1 34 are gi ven th e

.

am —
ounts of fresh zinc needed by a 1 00 and a 60 ton k et tle i n addi ti on t o
those ob tai ned from the second cr usts of the pr ec edi ng ket tle ch arges wi t h -

sof tening f ur nace l ead b ulli o ns varyi ng i n th ei r Ag co nt ents

-
Tables 1 35 and -
.

1 36 gi ve th e am o unts of z i nc need ed to co m pl etely d esi lv eri ze th e k et t le

contents ; the am o unts are governed by the hot and cold sam ple assays as -

was the case i n Table 1 31 .

EXAH PLE C

TAB LE 1 34 —.FI RST ZI N C ( 1 00 and 60 ton ket tles)

-

Pounds zi nc to be added
‘

1 00
-
ton kettle 60 ton kettle
-

m
E xa ple D — Th i.s plant desilveri zes —
i n 60 ton kettles Table 1 37 gi ves .

the amo unt s of fresh zi nc need ed wi th sof teni ng f ur nace charges assayi ng -

from 35 t1 o 2 9 5 oz Ag (Au) p er ton and states th at 6 lb z i nc are to be added

.
,
.

for every ounce si lver (gold) i n excess of 2 95 oz Ag ( Au) p er ton Table 1 38 . .

g i v es t h e z i nc n e ed ed i n th e se co n d z i n ck i ng .I n c a se a k e t tl e i s n ot com

p l et ely d esi lv er i ze d by t h e seco nd z i nck i n g as

, h app en s occ as i o n a ll y t h e r e are ,

g i v en i n T a ble 1 39 th e a m o u n ts o f z i nc n ee d ed to clea n t h e k et tl e by a

thi rd zi nck i ng .
536 ME TALLURGY OF LEAD
Bu m s D
TAB LE 1 38.
— SECO ND ZI NC ( 60 -
ton kettle)

Ex AuTLE D
TABLE 1 39
— Tarn . ZI NC
( 60 ton kettle)
-

Cold Sa plem
assay, oz Ag
.

p er ton

2 47 Desi lveri zi ng Kettles

.
— The k et tl es used for desi lver izati on are usu
mm
ally spheri cal ; so eti es th ey are elli p so i dal Th ey are fro 3 ft t o 3 ft 6 i n
. m . . .

deep, thei r di amters va yi ng

e r wi th the requi red cap aci ty Th e early vessels .

used were the 1 5 ton kettles i n the Patti nson process i n whi ch the labor i n
-

volved dem anded a kettle of not gr eater dep th th an 3 ft ; stirri ng i n of zinc .

by h and requi red a ket tle of about the same dep th ; em p tyi ng a kettle by m eans

of the S tei tz si phon (see below) li m i ted the dep th of a k et tl e to 3 ft 4 in as . .

,

air at 760 m .m pressure wi ll not balance a hi gher column of lead Wi th the in .

venti on of the H oward sti rr er (Fi g s 57 1 573) and the M i ll er centr i f ugal pum
.
ps

( F i g.s 6
5 3 the or i gi nal l i mi t of 4 0 i n t o the d
. ep th h as been aboli shed so

that one m ay exp ec t deep er k et tl es .

S ti rr i ng i n zi nc by h and r estri c ted the capaci ty of a k ettle to perhaps 40

tons lead ; w i th the advent of th e H oward sti rr er k ettl es were i ncreased in
,

si ze to hold 60 and ev en 1 00 tons sof tened lead b ull i on .

 DE S ILVE RI ZA TI ON OF LEAD B ULLI ON 537

Kettles lly of cast i ron whi ch i s dense strong and tough ; they are
are usua , ,

best cast bottomdown Thi rty ton k ettles are 1 16 to 2 i n thi ck thro ugho ut ;
1
.
-
.

th ey have b een m
.
ade 2 15 i n th i ck at the bo t to mtaper i ng to I }é to 2 i n at the
. .

ELEVATIO N OF THE FRO NT O R Fl Rl NG S IDE vent i on S ECTION ON

. VERTICAL S ECTION O N
TH E LINE c D -
TH E LINE E F -

“0 1 " n o

HORIZO NTAL S ECTIO N O N THE LINE A B

CASTINGS o; DOOR FRAMES
-
-

FIR
' ’ '
12 o s o o
A?

ELEVATIO N
O F KETTLES LINE G H
-

KETTLE FO R LIQ UATED

FIGS 52 5 to 554
. .
— D esil veri zing and li quati ng kettles , Nati onal S melting and Refini ng Co .
,

South Chi cago, Ill .

ri m . Uni for mi ty in thi ckness i s more common Sixty and 00 ton kettles are . 1 -

h eavi er . A ca t i ron kettl e lasts fro m to 15 y ears wh n i n conti nuo u use

s -
1 1 e s .

Steel kettles have not found favor i n th e Uni ted States ; th ey are i n use in
1
Lane, Eng M i n J . . .
,
1 9 1 2 , xc m3
, 21 .
538 M E TALLURGY '
OF LE AD

s o me E uropean works i n whi ch the lead i s refined by steami n the same k et tle
i n whi ch i t has been desil v er i zed and gi ve sati sfac ti on , .

Fi gs 52 5 554 gi ve the details of th e 30—ton desi lveri zi ng kettles an d th e

.

li quati ng ket tles formerly used at th e N ati onal W orks South Ch i cago I ll A , ,
.

ket tle i s usually susp ended by i ts ri m whi ch rests on a ci rc ular cast i ron ri ng ,
-

coveri ng the top and si des of a bri ck wall Fi gs 54 5 54 9 550 Sho w t hr ee . .

, ,

sup p or ti ng ri ng s for the d esi lveri z i ng k ettle the li q uati ng k ettle and t he , ,

li q uated lead kettle The casti ng ( Fi g 54 5) consi sts of four separate p i eces
-
. .
,

VERT ICAL OEOTIO N OF DES ILVERIZINO KETTLE

ELEVATION OF KETTLE , FLUE AND PLATFORI

FIG $57 .

F10 556 .

FIGS —Si xt ton ci rcular desil veriz i n ket tle coal fired
555 to 55 7 y g
- -
. .
, .

shown i n sec ti on by Fi g 54 6 They are fastened togeth er by bol ts passi ng

. .

thro ugh flanges as seen i n Fi g 54 7

, The casti ng r ests on the worki ng pla tform
. .
-

of the kettle as shown i n th e front elevati on ( Fi g

, I t is m ade 9% i n . .

wi de and i ncloses th e 9 i n wall whi ch r i ses 1 8 i n above the mai n br i ckwork

,
-
.
, . .

W i th many k et tles the sup por t of the ri mco nsi sts of a c i rc ular i ron ri ng cov eri ng ,

o nl y the top of the br i ckwork whi ch must be th i ck er than 9 in if i t i s not to

, .
,

g i v e wa y to th e p r ess ur e of th e w ei gh t of the k ettl e fille d w i t h lea d T h e si d e .

wall th us of ten reach es a th i ckness of 1 8 i n th e i ro n sup p or t r i ng ei ther enti r ely .

,
-

coveri ng i t or leavi ng 2 or 3 i n exp osed 1

The p lace fromwh i ch the k et tl es are
. .

1
M uller ( B erg H il ttenm Z 1 889 X LVI II 2 1 8) gi ves i t as h is experi ence t hat a k ett le
. . .
, , ,

m
lasts longer i f suspended fro a ri b cast on t he k ettle at half i ts dep t h T h is ri b would t hen .

m
for the parti ti on wall between the fireplace and the enci rcli ng flue, whi ch si plifies t he m
const ruct i on of the bri ck -
work .
540 ME TALLURGY OF LE AD

bri ck wi th a half course of low gr ade fire bri ck carry a h eavy cast i ron p la te
- - -

,
-

whi ch supp or ts the ri mof the ket tle Beneath the ket tle are a sand fill sh a p ed .
-

to th e formof the ket tl e and tw o flue wall s The firi ng door i s 1 8 i n w

, i de ; th e -
.
-
.

flame travels backward between the two flue walls p asses to the lef t ( Fi g 5 -

, .

enc i rcles the upp er p ar t of th e k et tle and th en enters th e flue The work i n g ,

pla tformis on the sam

.

e l evel as th e floor of th e sof teni ng f urnace ; the v er t i cal

di stance between the floors of the sof teni ng and r efini ng f ur nac es i s 1 1 ft 9% i n . .
,

a stai r c ase co nnec ti ng th e tw

.

-
o .

I n Fi gs 558 560 are gi ven a horiz o ntal and tw

. o ver ti cal sec ti o ns of an o v al

oil fired 80—

-
ton desi lv eriz i ng k et tle 8 by 1 3 ft and 3 ft 6 in deep and i n Fi g 5 6 1 , . . .
, .

the detail of the band whi ch encloses the ket tle fram e The hori zontal sec ti o n -
.

Fi g 558 shows a fram

,

.
, e work of h eavy T shap ed c asti ngs whi ch are ancho re d
- -

i n the ground and ti ed at the top s wi th a sof t steel band rep resented i n F i g -

5 6 1 .I n th e fr ame i s er ec t ed th e br i ck w al l wh i ch c arri es th e k et tl e The w a ll .

J 0111: for B and A round Tap of Kett l e Fra e m

FI G — D etail for band of eighty ton kettle FI G 6 — S i l d i h
56 1 5 2 t e tz ea s p o n
-
. . . . . .

is covered by heavy cast iro n plate wi th flange whi ch enclo ses the tops of th e
a -

frame The h ea ti ng chamber or lead p i t has the formof an i nver ted arch ;
.
,
-

i t i s provi ded wi th an entrance 3 ft wi de The k et tle i s h eated wi th three . .

Oil b urner s tw
-
o p lac ed near one end of the ket tle and the th i rd near the o th er
,
.

The p roduc ts of com busti on are wi thdrawn thro ugh three p or ts ; two end i n
9 b y 1 2 i n fl u es of
-
N o 1.
4 st eel p late wh i ch d el i.v er th e g ase s t o th e m a i n dow n
tak e; the th i rd i s close to th e lat ter wh i ch passes i nto a m ai n flue under ,

gro und connected w i th a chi mney

, .

D esilveri z ing k ettles w ere form erly em p ti ed by a di scharge p ipe cast i n the -

bo ttomof the ket tle and r unni ng out thro ugh the bri ckwork I t was closed .

ei th er by a sli de valve on the o utsi de (si m

-
i lar to the lead di scharge of the Luc e
Rozan crystalli zer ) or by a clam p a nd th u,m b s cr ew on th e i ns i de I n 1 8 77 A .
,
.

S tei tz i nvented hi s siphon wh i ch qui ck ly r ep laced th e tap p i ng sp o ut and unti l

1
,

recently was p referable to any o ther means for emp tyi ng a kettle A common .

for mof i t i s shown i n Fi g 56 2 I t consi sts of a p i ece of gas p i p e a fro m2

. .
-

, ,

to i n i n di am eter bent so as to r each fro mth e ri mof th e k et tle to th e bo t tom

.
,
.

H ere i t has an elbow b scr ewed to i t to p revent the lead co lum

, ,
n fro mbr eak i ng .

To the o th er end i s at tached al so by an elbow c the v er ti c al sec ti on arm d , , ,

-

, ,

havi ng a cast i ron stop cock e near the lower end The si p hon di scharges the
- -

, ,
.

1
U S Patent, No
. . . 1 9 699 7, N ov . 1 3, 1 8 77 .
 DESILVE RI ZATI ON OF LEAD B ULLI ON 54 1

l ea d i nto aof c
ast or a channel i ro n or an I beamwhi ch
-
i ro n trough -
i n iron .
- -

ca rr i es i t i nto the refini ng f ur nace .

Si nce the advent of the Mi ll er centri f ugal lead p um p the Stei tz si phon
i s bei ng r ep laced by the for m er wh er ever condi ti ons p er m i t thi s exch ange ,

as i t em p ti es a kettle very qui ckly e g 60 tons lead i n from 1 2 to 1 5 m in , . .

, .

t h ro ugh a 2 i n p i pe the sh af t dr i ven by a 1 0 h p m

-
. o tor maki ng 800 r p m
,
-
. . . . .

T hi s p um p w as i nstalled i n 1 9 5
0 a t Tr ail B C ; i t r ep laced the Roesi ng p um
1
p 1
,
. .

whi ch had been i n operati on and had gi ven much trouble on account of ,

r epai rs and the formati on of large am o unts of dross The p um p i s an i ron .

FI G 563 .

FIG S64 .

FI G S 563 to .
566 — . M iller centri fugal lead p u p m and support .

ver ti cal sub merg mp N o ed centrif ugal

whi ch has a uc ti on of in p u , . s .
,

and a di ch arg e of 5 i n
s i n di am i r a ted a t 5 g
0 a l w a t
2er p er
. m i n a n.d .
,
s 1 . .
,

co t $55 The p ump i s run at from400 to 500 r p m dep ndi ng upon the
s s . . . . e

am o unt i t i s de i r d to rai e i n a gi ven ti me At Gr a elli I nd a si mi lar

s e s . ss , .
,

p um p 8 i n i n d i am ter w i th. a i n d i ch a rg i i n op er a ti o
e n for m o ldi n g b ar 2 -
. s e s s .

In or der have an even flowof

to ver ti cal stand p ip e i n wh i ch the lead lead , the -

ri ses has a spec i al discharge openi ng i n the si de By keepi ng the lead i n the
,
.

ppi e abov e th e d i sch arg e o p e n i ng th er e i s an ev en fl ow t hro u gh t h e m oldi ng ,

p i p e wh i ch fill s t h e m o lds u n i for m l y and do es away wi th splash i ng or S lopp i ng .

1
Mill er E ng M i n J . .
,
1 91 3, x cv, 3 86 .

mZ
.
,

1
E ng M i n J
. 1 885 . .
, , X L, 3 66 ; B erg H utten .
'

. .
, 1 889 , X LVIII ,
2 62 Z
; t B erg H ittt S al
. . . .

W i . . Pr ,. 1 89 3 , x m ,
2 84 .

1
Ru mey and C
s o .
,
Ltd .
,
Seneca Falls, N Y . .
54 2 =
ME TALLURGY , OF LE AD

A M ll r p
i e u h m
p wi t i ts fra e work i s shown i n Fi gs 563 566,
— m -
. and th e i m
peller and shaf t in Fi gs 567 and 568 The fra e (Fi gs 563 and
. . m . 1 2 ft l o ng
.

by 5 ft 2 14 i n and 4 ft 6 in hi gh i s handl e
. . . . erhead crane ,I t ca rri es d froman ov .

i n the c enter a di vi si on 2 ft squar e w hi ch holds an 8 i n p i pe to whi ch i s a t

, .
,
-
.

tnched a 1 2 i n casi ng wi th foo t p i ece and a 2 i n deli v ery pi pe ( Fi gs 565 a n d

-
.
- -
.
-
.

The I 2 i n i m p ell er (Fi g 6

5 7 a nd 68 ) i t t h d t v r t i c l h f t
5
-

s . s a ac e o a e . a s a ,

1 % i n i n di am eter wh i ch i s dri ven by a ver ti cal I O h l r c m o or

.
, p e ec t i t ( n o t -
. .

shown) at the r ate of 800 r

p m W h en i n op e ra t i on . th e fr am
. e r .est s u p o n t h e

ri m of the ket tle; a steel plate pl atform 30 i nwi de on ei th er si de Of the ce n

,

, .
,

tral di vi si onprov i des a standi ng place for the attendant .

FI GS .
56 7 and 568 — I . mpeller of M ill er lead p u mp .

248 . Li quati ng Apparatus — In connec ti on wi th the desi lveri zi ng kettle must

be di sc ussed the appar atus req ui red for li q uating the zi nc cr usts . Three have
been i n use The last has
. abo ut replaced the o th er tw o i n use .

The first i s shown i n Fi g s 552 554 p ag e 53 7

— I t consi sts of a shallow
.
,
.

kettle placed on the sam e lev el w i th the desi lveri zi ng kettle and close to i t .

Th e bo ttomi s convex i n the center i n order th at the di sch argi ng spo ut m ay ,

be shor ter th an wo uld be possi ble if the kettle had the usual sph er i cal form .

Form erly a perforated cast i ro n di sk ( an old ski m mer) was p laced i nsi de th e
-

ket tle over the openi ng i nto the spout to prevent p arti cles of cr ust fro mpass
, ,

i ng ofl w i th the l i q ui d lead ; th i s h as been gi ven up at som e works as the ,

perforati ons easi ly beco me clogged and when open do not prevent fine p ar ti cles ,

frombei ng carri ed ofl by the li quated lea d Thi s r uns fromthe spout i nto a .

sm all sph er i cal k ettle whence i t i s bai led out af ter i t has been sk i m
,
med .

The draw i ngs gi ven i n Fi gs 4 9 7 and 4 98 show forevery desi lver i z i ng k ettle one
.

li q uati ng ket tle wi th i ts li q uated l ead k ettle Thi s p resuppo ses that no di s -
.

ti nc ti on i s m ade b etween gol d cr usts and S i lver cr usts Where the cr usts are .

k ep t sep arate the desilveri zi ng kettle wi ll have a li quating kettle on ei ther si de

, ,

one for the gold cr ust th e o th er for the sil ver cr ust ; the li q uated cr usts as w ell
,
544 ME TALL URGY OF LEAD

the exc ess lead carri ed by the crust whi ch flows back i nto the kettle; and th e
,

ring i s then attach ed to the plunger The whole apparatus i s nowswung t o

.

one si d e the bo tto mpla te carryi ng the sq ueezed cr ust i s low ered til ted by
,
-

means of a lever and the crust dumped The bo ttomi s returned to i ts ori gi nal
,
.

p o si t i o n ; the p lun g er c a rry i ng th e ri ng i s rai sed th e bo t to m,followi ng s ui t unt il

i t encloses the plunger ; th e ri ng i s detach ed fromthe pl unger and rests agai n
on the perforated botto m Th e appar atus i s now r eturned to i ts ori gi na l
.

o i t i o n ov er th e k e t tl e an d low er ed unti l the r i ng i s p ar tly sub m erg ed i n th e

p s ,

FI GS . 6
5 9 and 5 70 — H o ward a
.lloyp ress .

lead when i t i s ready to recei ve fresh crust The dumped cr ust i s easi ly broken
, .

to nut si ze p i eces wh i le hot so th at i t m

-
ay be charg ed i nto t he r etor t
,
Th i s .

may be done by flatteni ng on the floor wi th the back of a shovel or worki ng

wi th a rak e or hoe Ano th er method i s to work the crust thro ugh a cast i ron
.
-

box 2 4 by 1 8 i n and 3 i n h i gh havi ng a bo ttom15 i n th i ck wi th op eni ngs 2 i n

, . .
, . .

sq uar e .

The press is used ahnost everywhere for freei ng r i ch si lver cr ust fromad
heri ng lead ; i t al so finds app li cati on i n rem ovi ng entangled lead fromdrosses
whil e th ey are bei ng ski mmed fromlead wh i ch has been melted i n a k ettle .

The advantages of the press are th at i t does away wi th li quati ng k et tl es and

,

reverberatory furnaces as well as all extraneous h eat thus gi vi ng more room ,

aro und the k et tl es and sim lif

p y g i n a n d ch eap eni ng the Op erati on (one p ress
 DE S ILVE RI ZA TI ON OF LE AD B ULLI ON 54 5

se rvi ng a number of kettles) ; that not bei ng oxi di zed the cr ust g i ves up i ts , ,

lead readi ly ; and that the li qui dated lead flows di rectly into the desi lveri z i ng
kettl e where i t belongs .

The prac ti ce of l i quati ng z inc crusts in a spheri cal ket tle wi tho ut a lead di s -

charge and remov ing the l i quated crust floati ng on the l i qui d lea d w i th a skim
mer is anti quated if the crust is to be disti lled ; and j ustly so as i t is i mpossible
, ,

to ob tai n i n th i s w ay a dry crust t hat is sat i sfac tory I f the tem p er a tu r e of t h e .

lead be raised sufli ci ently h i gh to ob tain a dry crust a consi derable quanti ty of ,

i t wi ll be redi ssolved by the lead I t wi ll ri se again to the surface when the lead
w
.

cools but i t will be ri ch i n lead and at the same

, e low i n si lv er
, Thi s m ethod .

i s i n Operati on wi th the second or final unsaturated cr ust whi ch i s cast i nto

molds and goes i nto the next kettle charge to take the place of par t of the new
°
-

zi nc that i s to be added .

2 49 Mode of Conducti ng th e Desilveri zati on and Results

.
— The lead bul
li on i s tapped fro mthe sof teni ng furnace run i nto the desi lveri ng kettle i n ,

abo ut 1 hr and i s th en drossed i n abo ut 2 0 m

.
, in I t r epresents about .

0
9 p er c en t of th. e b ulli o n ch a rg ed i n t o th e sof te ni n g f u r n ac e T h e b u ll i o n .

i n the k et tle i s heated abov e the m el ti ng po i nt of z i nc ( 4 1 9

°
i f neces-

sary ,but usually i ts tem perature i s already hi gher th an that of the kettle .

The dro ssed b ulli o n rec ei ves 1 0 i tons of floor zi nc i e the unsaturated zi nc ,
. .
,

crust froma precedi ng second zi ncki ng whi ch has been ski m med i nto molds ,

say 1 8 by 4 8 by 9 i n The cak es are m el ted i n about 1 hr th en slab s of spel ter

. .
,

for the fir st zi ncki ng are added and mel ted and the whole sti rr ed mech ani cally , ,

for abo ut 2 0 m i n The ri si ng crust i s skim . med and pressed at a tem

p e ra t ure of 4 80 to 5 1 0 C i n fro m 1 t o
°
h r
. .

At som e work s the floor zi nc is first charged i nto the k ettle ; when m ol ten ,

ther e i s added the sp el ter ; and th en only the lead bulli on tapped i nto the k et tl e
fromthe sof teni ng furnace; and the whole stirr ed for 2 0 to 30 m in Op erators .

followi ng thi s m ode of procedur e find or beli eve that the desi lveri zati on pro
g re ss e
s m or e q u i ckly a nd sa t i sf ac tor i ly .

Whatever m ay be the sequenc e of ch arging th e k ettle wi th lead b ulli on ,

unsaturated zi nc cr ust and spel ter the cr ust and spel ter have to be i ncor
, ,

porated i n the lead b ulli on i n order to bri ng the zi nc i nto i nti ms te contac t
wi th the preci ous m etal ; and thi s i s accom p l i sh e d by st i rr i n g .

At som e works followi ng th e exam ,

ple of Rah t there i s added to the kettle
1
, ,

before sti rri ng a shovelf ul of salam , moni ac about 1 lb to 1 0 tons of lead as i t , .

,

i s sai d to co unterac t oxi dati on of cr ust and to assi st i n k eep i ng the tools Clean .

Attenti o n m ay be call ed to the use of thi s sal t by Roessler and E d elm

1
ann ,

i n th eir exp er i m ents upon th e Roessler E d elm ann process to fr ee zi nc

-

cr ust fro moxi di zed materi al .

H and sti rri ng Form

-
—
erly all zi nc used to be sti rr ed i n by hand ; thi s i s sti ll
.

done at so m e work s w i th th e second zi nck i ng I n the late sev enti es steam .

was first used by E nri ch at the works of the Pennsylvani a Lead Works ,

1
U S Patent N o 8 2 6 1 1 4 , J uly 1 7, 1 906
m
. . . .

1
B erg H utten
. m
Z 1 890, x x , 2 4 5 . .

85
546 M E TALLURGY OF LE AD

Carnegi e, Pa .
, and hi s exa mpl wa
followed by o ther plants Thi s meth od
e s .

has had to gi ve w ay to the H ow ar d m ech ani cal sti rr er .

In hand sti rri ng a paddle i s used consi sti ng of a perforated disk 1 2 i n i n

-

, , .

di ameter ri veted to a handle 6 ft long havi ng a cross p i ece as hand hold

,
.
,
- -
.

Tw o m en standi ng oppo si te ea ch o th er do the sti rr i ng They i nser t the paddl e s .

ver ti cally at the ri mof th e k ettle push themdownward towar d the center then , ,

rai se them using the ri mof the kettle as a f ulcrum and draw them wi th the
, , ,

di sks gli di ng on the lead fro mthe center toward the periphery gi vi ng the lead
, ,

a ro tary m o ti on; thi s they rev erse every five m i nutes and th us i nsure an i nt i ,

mate mi xi ng of zi nc and lead Thi s sti rri ng i n whi ch lasts fromone half to .
-

,
-

th ree q uar ters of an ho ur i s h ar d for the m

-
en ,
.

S teamsti rri ng T he efl ect of steamwh en i ntrod uced i nto lead co ntai ni ng

— -
.

zi nc vari es w i th the tem perature of the lead .

1 If the tem
. peratur e of the lead be below the mel ti ng poi nt of zi nc i e -

, . .
,

the tem perature when the kettle i s skimmed the steamwill bri ng to the surfac e ,

a zi nc cr ust and wi th i t som e of th e si lver co ntai ned i n the lead

,
.

2 If th e tem
. peratur e be sli gh tly above the mel ti ng poi nt of zinc ( sti rri ng -

i n ti m e) the steamwi ll cause a thoro ugh m

,
i xi ng of z i nc and lead .

3 If th
. e t e m p e r at ur e be b et w ee n a da rk red and an i nci p i ent cherry red - -

the steamwi ll cause a sc umto ri se contai ni ng about 3 p er c ent Zn wh i ch does ,

.
,

not however take any si lver away fromthe lead

1
.
, ,

4 If i t.b e a cle ar ch e rry re d th e z i n c w i ll d e co m p o se

-
th e stea m,; th e r esul ti ng
zi nc oxi de ( m i xed wi th lead oxi de) collec ts as a powder on the surface of t he
l ead .

The steamm ust be absol utely dry if vi olent exp losi ons are to be avoi ded .

The condensed water i s separated by a steamtrap placed beneath th e worki ng

platform To the ver ti cal pi pe com
. i ng through the platformi s f astened by
means of a coupli ng a small pi ece of pi pe to whi ch i s joi ned by two elbows (wi th ,

a ni p p le i nterv eni ng ) a hori z ontal p i pe whi ch r each es to th e cent er of the k et tl e , .

An elbow connec ts i t wi th the ver ti cal pi p e that wi ll reach 2 4 i n i nto the ket tle ,
.

when i n place Before the steamvalve i s opened the ver ti cal pi pe i s turned
.
,

up i n or der that the steamm

, ay first pass out i nto the ai r to warmthe p i pe and

to exp el any condensed water The p i pe i s then turned down and wei gh ted
.

wi th a bar of lead to keep i t i n place When the steami s tur ned on the waves .
,

of lead caused by the first ascendi ng b ubbles wi ll dri ve the z i nc floating on th e

lead toward the ri mof the kettle and hardly any of i t would become incorp o ,

rated wi th the lead if i t were not pushed toward the center of the kettle to be ,

drawn i nto the lead by the downward c urrent close to the steampi pe Th e -
.

zi nc cr usts th at r i se to the surf ace soo n af ter sti rr i ng i n has begun are also , ,

p ushed to war d the center that they may take up more si lver Th us the zi nc , .

and th en th e cr usts pass down at the center and com e up agai n near er the ci r ,

cum ference of the k ettle wh ence th ey are agai n p ush ed toward the center
, .

The tool used for thi s purpose i s a wood en hoe consi sti ng of an i nch board , ,

I 2 by 1 8 i n i nto the c enter of wh i ch i s i nser ted an i nch lath fro m

.
, 8 to 1 0 ft long . .

1
Roesi ng, Zt B erg B atten S al . . . . W . i Pr ,
. . 1 889 , mm , 76, 77 .
548 ME TALLURGY OF LEAD

By the ac ti on of the propeller the metal i n the i nclosi ng c ne i s

o forced o ut a t
the bo ttom bei ng cons tantly r epleni sh ed from the top Thus
,
. a perfect ci r

culati on and sti rri ng i n first of the zi nc and of the zinc crust that has risen t o ,

the surface i s ob tai ned i n the shor t space of 1 0 m

,
i n wi th a 30 ton k et t le and .
-
,

i n from2 0 to 30 m i n wi th a 60 or 1 00 ton ket tle By rever si ng the en gi ne

.
-
.

the flow of m etal wi ll be in th e opposi te di rec ti on As the ai r i s alm ost co m .

p lete ly e x cl u d ed th e o xi da ti o n of z i nc a,
nd l ead i s gr ea tly r ed uced .

The sti rr ers used at pr esent are wi tho ut cover as thi s m akes the appara t us ,

cumbersome and as th e advantages exp ected fromi t have not been f ully rea l
,

i zed . I t i s true that som e o xi d e i s for m ed wh i ch coll ec ts i n a sm all heap on th e

cr ust at center but the amount i s i nsi gni ficant ,

.

M ost refineri es have also gi ven up the central cone as wi th the p ropell er ,

sh af t r unni ng at th e r ate of 1 30 to 1 40 th er e i s form ed a vor tex nea r ly as

large as the cone I t also has been found that reversi ng the ro tati on of the sh af t
.

i s unnecessary .

In outli ne the m ode of op erati o n i s as follows : Wh en the sof tened lead bul
li on i n the k ettle has been drossed and bro ugh t to r eq ui red tem perature cak es ,

of cr ust fromthe p recedi ng second zi nck i ng are charged and the newzi nc ,

add ed T he tem
. perature of metal bath o ught to be about 900 F = 4 8 2 °
.
°

The H oward sti rr er whi ch has been lower ed and p ut i n place i s ro tated fo r
, ,

fro m2 0 to 30 mi n ; i t takes some ti me for the floati ng zi nc cr ust fromthe charged

.

cakes to become thoro ugh ly i ncorporated The first crust i s now taken and .

pressed hot in a H oward press i n from1 36 to 2 hr H ot and cold sam fl e

s are .

tak en and assayed The second zi nc addi ti on i s m . ade and sti rr ed i n w i th th e

H oward m ach i ne The k et tle co ntents are now cooled by bank i ng the fire
.
-

under th e k ettle and by spr ay i ng water at center on the surface of th e m

, etal ,

bath froma ,
i n p i pe whi ch has sm all perfor ati o ns on the lower si de and i s
-
.

closed at the end The cr ust i s taken ofl i n from1 15 to 2 hr . .

I n sti rr i ng i n the zi nc i t i s of i m por tance that th e lead have the correc t

,

tem perature; if the latter i s too low the zinc wi ll be i mperfec tly i ncorporated ; ,

i f too hi gh the crust will run too low i n preci ous m

, etal Whether thi s i s due .

to the cr ust tak i ng up lead or the lead di ssolv i ng cr ust i s not defini tely k now , n as ,

the beh avi or of Aa s i n th i s r esp ec t has not been studi ed The work of .

Alder W r i gh t and Thom pson Kr eman and H ofmei er and Bagi tsch lead o ne
1 ‘
-
1 1
, ,

to beli ev e th at the cr ust i s di ssolv ed in lead Refiners sti r the zi nc i nto lead .

bulli on whi ch h as been brough t to a tem perature rangi ng from4 80 to 51 0 C

.

°
.

Large scale tests by N ew ton have shown th at i n sti rri ng i n the zi nc at 70 5 C

‘ °
-
.
,

over 40 C above the freezi ng poi nt of Agzzna and removi ng fromthe crust the
°
.
-

exce s s lead w i th a H oward press the assays of the cr ust or rather of the resul ting
-

retor t bulli on i ncr eased wi th temperatures falli ng to about 500 C and th en

,
°
.
,

d ecr eased owi ng to the i nabi li ty of the pr ess to remove the excess lead at the -

1
Proc Roy S oc , 1 890, X LVIII , 3 2 ; E ng Mi n J 1 890,
. . . . . L, 71 8 .

1
M onatshefte fur Che i e , 1 9 1 1 , xxxv , 563, 59 7 m
m
.

1
m
Co pt rend , 1 9 1 4 , a ,
1 78 1
. . .

1 Tr A I . . . M . E .
,
1 91 5, LI , 786
.
 DE SILVE RI ZA TI ON OF LE AD B ULL I ON 549

p r evai li ng low mp
te r
e atu e r of 4 00 to 4 30
°
C, . e en v wi th a pressure of 90 lb .

p er sq . in .

It was formerly the customto cool the lead af ter each zinck i ng i n order that
th e crust m i gh t separate as m uch as possi ble fromthe lead and be ski m med ofi ,

com pletely Thi s prac ti ce whi ch takes abo ut 3 hr for every z i ncki ng prevai ls
.
, .
,

wi th the second crust but has been abandoned wi th the first as already shown
, ,
.

W hen the first zi nc has been i ncorporated i n the lead th e ket tle i s ski mmed ,

wi th the fire kep t goi ng on the grate Wh en ski mmed hot (gumdrop) and
m
.
,

cold samples are tak en The hot sam e i s pour ed fromthe ladle as soon as i t
.

h as been tak en ; the cold i s po ured af ter the ladl e content h as cooled sufi ci ently -

t o allow all the cr ust to r i se to the surf ac e and to p er m i t casting a sam ple of
clean lead The cold sample represents the condi ti on i n whi ch the lead i n the
.

k et tle would be after cooli ng and ski mmi ng all the cr ust The zi nc necessary .

for the second zi nck i ng i s fo und i n Tables I 31 1 33 1 3 5 and 1 38 By tak i ng hot , , .

and cold sam ples and proceedi ng wi thout cooli ng the kettle a consi derable ,

sav i ng i n ti m e i s attai ned At pr esent the tw o usual z i nck i ngs r eq ui r e 8 ho ur s

.

excl udi ng the i nfl ow of the lead but i ncludi ng the outflow Wi th the older , .

method of operati ng each ck g of 6 ton kettle lasted not less than 6

z i n i n a 0—
, ,

and of ten 8 ho ur s .

When the first zi nc si lver crust has been removed and the second zi nc has
-

been added and sti rr ed i n i t is necessary to remove all the crust that can be ,

made to ri se to the surface For thi s purpose the kettle content has to be cooled .
-
.

Usual ly the fire on the gr ate i s rem oved or dam ped wi th slack coal and the ,

fire and ash p i t doors and the dam -

per i n the flue are thrown wi de open that air
,

may rush through the fireplace and cool the k ettle .

A num ber of devi ces for hasteni ng the cooli ng have been tri ed but had to ,

be gi ven up Th us Meyer used water cooled p i pes bent to the sh ape of the
1
.
-

kettle Others have blown ai r on to the lead through a pi pe 4 to 5 i n i n

.
, .

di am eter suspended v er ti cally so as to be abo ut 3 ft abo ve the bath

, Water i s . .

freq uently spr ayed on to the lead as shown above ; and the last two blocks of ,

seco nd crust fro mth e pr ecedi ng ch arg e are added to assi st i n the cooli ng ; i n

ad di ti on steami s blown thro ugh the b ath whi ch also assi sts i n rai si ng to the ,

surf ace the last par ti cl es of cr ust .

When th e lead has cooled sufficiently for the crust to adhere to the si des
of the ket tle the cr ust is rem ,
oved wi th a ski m mer ; i ts di sk made of in ,
-
.

i ron i s from1 5 to 1 8 i n i n di am
,
eter and the h andl e of 1 16 i n gas pi pe i s 7 ft
.
, ,
-
.
-

,
.

long havi ng a cross pi ece as hand hold The work i s faci li tated by suspendi ng
,
- -
.

the ski m mer froma book whi ch acts as a lever ; or the kettle ri mhas a fork ,
-

whi ch acts si mi larly Two men work together One man wi th a wooden h oe
. .

pushes th e crust toward hi s par tner who takes i t up wi th the ski mm er , .

Before disch argi ng i t i nto the H oward press or the m o ld i t i s i mpor tant that ,

the sk i m mer be well j erked several ti mes i n order that as much lead as possi ble ,

may be dr ai ned 03 into the kettle and the crust ob tai ned become dry Toward ,
.

the end of the Op er ati o n both m en h av e to work v ery slowly and car ef ul ly to

1
Mi n . S c Press,
. 1 88 2 , NO 5 ; Berg H atten
. . mZ . .
, 39 1 . 1 882 , X LI ,
550 ME TALLURG Y OF L E AD

a voi d p ushi ng the crusts back agai n i nto the lead whi ch wo uld retard the wo rk ,
.

When the cr usts have been removed fromthe surface the alloy adh er i ng to t h e ,

si de of the k et tle has to be bro ugh t to the surface T hi s is do ne by scr ap i n g .

the k et tle first wi th a ch i sel poi nted bar and then wi th a wooden lath
,
-
T he .

blade of the bar i s of steel 2 by 4 in and the handle of 1 i n round iro n

,
.
,
-
. .

Ski m mi ng and scraping are generally repeated twi ce af ter whi ch no mo re ,

crusts wi ll ri se to the surface I t takes from 1 to 2 hr to performth is . .

operati on Wh en fini shed the fire under the ket tle i s star ted and the ket tl e
.
, ,

heated up for the nex t zi nc Th e ti m e requi r ed for h eat i ng i s I to 2 hr

. .

The seco nd crusts are usually collec ted i n m olds or discharg ed on a whi t e
washed i ron plate Such a mo l d .

i s shown i n Fi gs 574 and 57 5 . .

Ther e the cr usts r em ai n unt i l

needed wh en the m olds are rai sed ,

and em p ti ed by m eans of a crane ,

or one end of a plate i s raised by

block and tackle and the crusts ,

are sli d i nto the k et tle .

Af ter each skim mi ng samples ,

are taken and 16 assay ton ,

-

sam ples are assayed for Ag to

check the progr ess of the desilver
i zati on Af ter the last si lver .

crust has been r emoved the assay ,

should show oz Ag p er t on .
,

or less if corrodi ng lead i s bei ng

made Should i t prove to be .

sli gh tly h i gh er say or oz , .

,

the i ntrod uc ti on of steamat the

FI GS 5 74 and 5 75
.
— Mold for zi nc crust
. low tem perature of the k et tle
.

af ter the last cr ust h as been tak en

03 ,
wi ll be effecti ve i n causi ng more si lver beari ng zi nc crust to be gi ven off -

by th e lead as sta ted above If the steami s used fromone half to three
,
.
-

quar ters of an ho ur the si lver contents of the kettle wi ll be reduced and

,
-

th er eby g ener ally an enti r e zi ncki ng saved .

The wei gh ts of the cr usts vary consi derably as do the am o unts of si lver they
tak e up . Assum i ng a 60 ton kettle and 1 50 oz lead b ulli on the first crust
-

,
-
.
,

wi ll wei gh 52 00 lh and the par tly desi lveriz ed lead wi ll assay 40 to 60 oz Ag

.
, .

p e r t on ; th e seco n d cr ust wi ll w e i gh to lb corr e s po n di n g t o fi ve .

cakes and the desi lv eri zed lead wi ll r etai n

, Ag p er ton .

The concentrati on of si lver from lead bulli on i n r etor t b ulli o n i s as

25 1 . One ton fresh lead b ulli on requi res lb or p e r cen t z i nc ; w i t h. .

th e second cr ust added to the k ettle thi s figure i s r educed to 1 4 lb or , .

p e r c en t T he old
. er pr ac ti ce req ui r ed 5 p er c ent z i nc T w o z i nc k . .

i ngs r eq ui re 8 hr excl udi ng runni ng in but i ncl udi ng r unni ng out of lea d
.
, .
552 ME TALL URG Y OF LE AD

the f urnace i s filled , th e fire i s urg ed for 3 or 4 hr . to bri ng the lead to a cherry
red, as a hi gh heat i s r equi r ed to burn 03 A bar i nser ted i nto the baththe zi nc .

sho uld be red hot af ter a few m i nutes The zi nc is par tly volatil i zed and.

carri ed ofl wi th the fumes and par tly oxi di zed and scorified by the li tharge
,

whi ch form s at the sam e ti me After heati ng abo ut 4 hr the surface of

. .

the lead wi ll be covered w i th a heavy li tharge li k e skim mi ng The doors are -

.

thrown Op en to cool the surf ace of the m etal the sk i m mi ng i s r emoved and , ,

a second heat gi v en af ter wh i ch cooli ng and ski m

,
mi ng are repeated A thi rd .

heat i s of ten necessary to slag the last traces of Zn and Sb When these are .

completely r emoved the li tharge drawn fromthe surface of the lead by means
,

of a r abble should be in large thi n plates I t should have whi le h ot a bri gh t

, .
, ,

yellow color when seen i n bulk and a greeni sh yellow when held up to the li gh t ;
,

no brow n spo ts ( anti m ony) should be vi si ble If thes e large flakes of li th arge .

sho uld b ecom e dark or show spo ts af ter h avi ng been expo sed for som e ti me to

the air the lead i s not sufi ci ently refined to sati sfy the requi rem
, ents for corrod

i ng lead .

A bar of lead m olded at the correc t tem peratur e should show on the surface
fern li k e crystalli ne forms the branches at r i gh t angles to the m ai n axi s If
m
-

, .

the lead i s not su ci ently r efined th er e w i ll formon th e surface i n addi ti on t o

,

the fer n li k e crysta ls sm

-
all bunches of crystals si m
, i lar to snowflak es whi ch ,

di sappear agai n when the bar soli difies com pletely leavi ng the surfac e finely ,

crystalli ne A ladle fil led and emp ti ed two or three times wi th lead wi ll show
.

i n the bowl the bl ue color of a bar of r efined l ead if all the i m puri ti es h ave ,

been removed Lastly a bar of lead wi ll of ten show on the lower si de of the li p
.
,

a bl ue color if the lead has been sati sfac tori ly refi ned al tho ugh the absence
, ,

of thi s color wi ll not prove that the lead is of i nferi or quali ty .

I n firi ng the refini ng f urnace i t i s essenti al th at the tem ,

perature to be
rai sed qui ckly to the necessary i ntensi ty and kep t there If i t i s allowed ,
.

to f all even a li t tle the b urni ng ofl of the zi nc wi ll be gr eatly retarded and

, ,

wi th i t the dependent operati ons .

In order to h asten the operati on steami s used In addi ti on to the m

, er e .

mechani cal eflect of sti rri ng i t ac ts chemi cally by bei ng decomposed by the
,

zi nc. I t i s i ntroduced thro ugh four or six 4 111 pi pes i nserted i nto th e lea d
3 -

thro ugh the doors so as to nearly touch the h ear th The steampr essur e is .

corr ec t when the lead i s thrown upward about 1 ft In order to ob tai n .

ski m mi ngs thoroughly melted and free froml ead i t i s essential to keep th e ,

tem perature hi gh ; if i t i s too low the ski mm i ng i s likely to be powdery and

,

filled wi th sho ts of lead Steam if ri gh tly used wi ll not i ncrease the am

.
,
ount ,

of ski mmi ng .

The r efini ng w i th steami s continued unti l all the zi nc has been oxi di zed .

Sk i m mi ng i s begun as soon as sufi ci ent oxi de has been formed and is conti nued ,

unti l the charge has been fr eed fro mz i nc Tw o m en e ach w i th h elp er rem
. ove , ,

the ski m mi ng and transfer i t i nto a p erforated p ot .

The ti m e r eq ui red for refini ng wi tho ut the use of steam r anges fro m1 0 to
. ,

1 5 hr ; wi th five or
. si x steamj ets i t is 6 or 8 hr i ncludi ng filli ng and
-

,
.
 DE S I LVE RI ZA TI ON OF LE AD B ULLI ON 553

emptyi ng of f urnace The .

refini ng ski m mi ng amounts

to abo ut 5 p er cent of .

the b ulli on charg ed and ,

contains about 90 p er cent .

Pb . At first i t i s dry, but

becom m es ushy toward th e
end of the process T he .

coal consumed i n r efini ng

used to be abo ut 1 2 0 lb p er .

ton of unsof tened b ulli on ,

correspondi ng to abo ut 7
g al of.r ed uc e d o il ai r b ei ng ,

used as atom iz er At pr es .

ent a 1 00 ton f ur nace b ur ns -

i n 2 4 hr abo ut 5 tons coal .

and tr eats three charges .

2 52 . Refini ng Desilver
i z ed Lead i n th e Kettle .

T he second of refin mthod

e

i ng desi lveri z ed lead i s the

one i nv ented by Corduri é ,

who i ntro duced steami nto

the l ead heated up to ch erry
'

r edness the oxi di z ed zi nc

,

collec ti ng i n the form of a

powder on the lead As the .

ai r canno t be excluded fro m

the surfac e and as i t i s al so ,

carr i ed i n by the steam ,

so m e of the l ead i s o xi di z ed ,

and the p ulver ulent y ellow

mass floati ng on the surface

consi sts of a m i xture of lead
and zinc o xi d e and finely

di vi ded sho ts of lead The .

co m posi ti on of these oxi des l

when tak en fro mthe k et tles

at the Lautenth al Sm el ti ng

and Refini ng Work s ( Prus

si a ) i s s oa Pegos
ZnO PbO
Pb p er cent .

l
Zt B erg H a n
. an S al . . W i
m
. . .

Pr ,. 1 89 0, xxx v , 2 72 .
554 ME TALLURGY OF LEAD

The lead bulli on at Lautenthal i s desi lveri zed wi tho ut previ o us sof teni ng ;
hence the h i gh p ercentage of Sb .

An analysi s of the oxi des tak en fromthe refini ng kettle of the Pueblo Smel t
i ng and Refini ng Co gave accordi ng to H oward : ZnO . Pho , Pb
p er c e nt .

The larg er sho ts of lead of the oxi des at Lautenth al are separ ated by screen
i ng the finer ones by wash i ng over an i ncli ned plane
,
The i m palpable powder .
,

form i ng p er c en t of th e whol e flo ats o fl a nd i s se.t tl e d i n v ats dr i e d i n a , ,

r everberatory furnace and forms a r eddi sh yellow pai nt of good coveri ng po wer
,
.

I t consi sts of 60 to 67 p er cent ZnO and 33 to 4 0 p er cent PbO The r esi d ual .
, . .

sho ts of lead are sm el ted at i nterv als for a second class l ead as th ey c on t a i n -

som e anti m ony .

At Lautenthal ( Fi gs 576 to 578) th e cast i ron k et tles ( 6 ft i n di am

l
. eter a nd -
.
,

3 ft . 2 i n d eep hol d i
. n g 1 2 5 4 m etri
,
c t o ns of l ead ) are h ea t e d a f te r th e de s il v e ri ,

zati on i s fini sh ed i n 4 hr to a ch erry red ; superh eated steam h avi ng a

,
.
,
-

pressure of from 2 9 to 36 lb p er sq i n i s then i ntrod uced thro ugh a ca s t . . .

,

i ron pi pe 2 bent to th e formof the k et tle so that the steamenters at the bo t to m

, , , .

Af ter 2 hr all the zi nc has b een o xi di z ed

. I n order to d ecr ease the loss of h ea t .

by radi ati on to k eep ofl the air and to prevent the o xi des fro mbei ng lost
, , ,

th e ket tle i s cover ed by a m ovable sheet i ron cyli nder whi ch has near the lower -

ri mt w o Oppo si te door s ( 4 % i n sq uar e) and the openi ng for the steampi p e .

,
-
.

I t ends i n a co ni cal hoo d whi ch leads the vapor and dust through a sheet i ro n -

pip e i nto the mai n flue termi nati ng in a d ust chamber The cyli nder wi th i ts , .
,

hood and pi p e i s suspended by a r unni ng di fl erenti al pulley froma traveler

,
.

For every 1 00 lb of unsof tened bulli on there are produced

. lb of pai nt , .
,

whi ch i s hi gher than the percentage of ski mmi ngs i n the reverber atory furnace ,

as the pai nt for m s but a sm all p ar t of the to tal l ead taken out of the k et tle .

I t used to be the p r ac ti ce to steam i n tw o stag es At first the door s i n .

the hood wer e k ep t closed so as t o exclude the ai r as m uch as po ssi ble Wh en .

the zi nc had b een oxi di zed th e hood w as r em oved and the oxi des were ta ken, ,

fromthe surface of the lead by means of a p erforated skimmer The h ood was .

th en p ut agai n i n place the doors wer e op ened and steam ,i ng w as r esum ed wi th ,

the obj ec t of r em ovi ng the Sb i n the formof anti mony ski m mi ng whi ch was ,

taken fro m the lead wh en th i s h ad cooled sufli ci ently The ch anges i n com .

posi ti on of th e lead whi ch take place duri ng steam i ng as gi ven by Wald eck ’
, ,

are sho w n i n Table 1 4 0 .

Par t of the s teamr efini ng plant of the Pueblo Sm el ti ng and Refini ng Cc .

,

Pueblo Colo i s show

,
n i n Fi gs 579 and 580
.
,
Th e kettl e 8 ft 1 % i n i n di am . .
, . .

eter and 3 ft d eep i s i ntended to tr eat 2 0 tons of desil ver i zed lead
, .
,
I ts rim .

has tw o concentr i c r i ngs form i ng r i dges betw een whi ch i s a groove to recei ve ,

the bo t tomof th e hood The air can th en be enti r ely excl ud ed by seali ng the
.

joi nt wi th sand or oxi des The sheet i ron hood i s rai sed and lowered by means .
-

1
Pri vate notes, 1 890 ; Ill ust rati ons from Schnabel Loui s -

,
“H andbook of Metall urgy ,

Macmi llan London , ,

1 90 5, I , 550 .

“Strei fz u e dut ch di e Blei und Si lberhtl tten des Oberharzes Knapp , Halle, 1 90 7,
g , 57 .
556 ME TALL URGY OF LEAD

w k
i ng ea i n heati n g u p th e l ea d to th e r e q u i r e d t e m p e r a t ur e a n d y i e l d i ng to ,

th e pr essur e i n steam i ng .

Instead of g
usi n stea m S a v elsb e rg i n t r od u c ed i n to th e p i p e a fi n e s p r a y of
water under a pressure of 40 lb p er sq i n whi ch i s conver ted i nto s tea m by
,

. . .

the eath of l
the ea d h
T e va e
. lv of the a w t e r m a i n a n d t he-
p i p e l ea d i ng i n t o
k l
the ett e are co c
nne te d by a copp e r co i l wh i ch ta k es u p t h e shock s c a u s e d
occasi onally by the admi ssi o n of
an exc ess of water wh i ch i s not

conver ted i nto steam .

For the success of freei ng de

sil v er i zed lead from zi nc i t is
essenti al th at the lead be k ep t at

a cherry red as th en th e z i nc-

, ,

and i nci dentally so m e lea d wi ll ,

be qui ckly oxi di zed and fl oa t on ,

top of the lead i n the form o f a

fine powd er readi ly rem oved wi th
a ski m mer If the temperat ure .

si nk s th e ti m e of steam,
i ng is
lengthened and the o xi de formed ,

wi ll be mushy and retai n a la rge

q uanti ty of sho ts of lead di ssemi
nated thro ugh i t Kuhl em ann
l
.

gave the fo llowi ng fac ts as t o t h e

eli m i nati o n of zi nc : Af ter steam
i ng hr th e lead r etai ned .
,

p e r c e n t Z n a f te r h.r , .

p e r c en t th e z i n cky l e
.a d ,
s t i ll
sho w i ng i ts ch ar ac ter i sti c of fla t
teni ng out r eadi ly ; w h en thi s ha d
d i sapp eared and the oxi des had
assum ed the for mof a dry po w d er ,

i e af ter 2 hr th e lead r eta i ned

. .
, .
,

FI G 58 1
.
— H ow
. ard ski m mer . p e r ce n t Z n M ore c o m .
“

p le te d a ta h a v e b ee n g i v e n i n
Tabl e 1 4 0 . The op erati on i s fini sh ed wh en the o xi des are po w dery and a ,

sam ple of lead taken up i n a ladle for ms clean golden yellow li tharge wh enever
i ts surf ac e i s exp o sed to the ac ti on of the ai r .

The o xi des are usually rem oved wi th a perforated sk i mmer whi ch i s a ,

leng thy and hot p i ece of work The op erati on i s v ery m

. uch si m plified by the
use of the H owar d ski m mer shown i n Fi g 581 Thi s was ori gi nally con
2
,
. .

str uc ted to rem ove the zi nc cr usts fromdesi lveriz i ng kettles a

I t has been .

Pri vate notes f romthe L autenthal Record of Analyses,

“
U S Patent No 50 2 , 1 2 2 ,
. . . J uly 2 5 ,
1 89 3 .

Mi n I nd 1 89 3, n, 44 0
. .
 DE S ILVE RI ZA TI ON OF LE AD B ULL I ON 557

replaced in most instances by the H oward pres s and i s nowused for oxi des I t , .

consi sts essenti ally of two parts : a yok e C wi th slo tted extensi on C carryi ng a , , ,
'
,

pai r of hi nged ski m mer leaves H of perforated boi ler i ron and a suspended ai r -

, , ,

cylinder A wi th piston rod B carryi ng a li nk N wi th two pai rs of rods 22 one

, ,
-

, , , , , ,

for each of the leaves The pi ston rod carri es a p i n D traveli ng i n th e slo t of .
-

, ,

the extensi on C and the extensi on has a lock M to m

,
ake a ri gi d co nnec ti on , ,

b etween the yoke and the pi ston rod ; th e ai r cyli nder has on the lower si de the -

ai r i nlet and opposi te to i t a latch L to secur e the proj ec ti on of C

'
.
, ,

Sup posi ng the kettle to be r eady to be ski m med and the ski mmer to be ,

im mersed i n the lead as shown in the figure compressed ai r wi ll be turned on, ,

t hro ugh the hose Thi s causes the pi ston rod to ri se and the leaves to unfold
.
-
.

The yoke rem ai ns stati onary and extendi ng into the lead prevents the leave s ,

fromturning Wh en the pi ston rod has opened the leaves p i n D wi ll have

.
-

, , ,

moved up in slot C to posi ti on D whereupon i t engages wi th the yoke exten

’
, ,

si on and pulls up the ski m mer wi th i ts load unti l th e proj ecti on of C is latch ed ’

by L I t i s nowpushed to one si de where the oxi des are to be unload ed For

.
,
.

th i s p urpose som e ai r i s let out of the cyli nder when the leav es wi ll drop the , ,

yoke r em ai ni ng la tch ed by L When the ski m mer i s to be used agai n i t i s .

,

bro ugh t over the k ettle the yoke lock ed wi th M to the pi ston latch L raised , , , , ,

and ai r let out agai n whereupo n the clo sed sk i m mer wi ll si nk i nto the lead
,
.

The use of com pr essed ai r makes the work very easy If sufi ci ent pressure .

canno t be had the ski mmer i s worked by hand substi tuti ng for the air cylinder
, ,

a co m bi nati on of r ack and o ther geari ng .

The great drawback of steam i ng zi nc beari ng lead i s the wear and tear on -

k ettles Accordi ng to Schm

. i eder at Tarnowi tz where the lead i s very fr ee
l
, ,

from anti mo ny cast i ron kettles last only for 2 0 charges but steel kettles
,
-

are good for 90 ch arges Th e li f e of cast i ro n refini ng k ettles var i es gr eatly ; .

-

extr em e figur es are 30 days and 1 2 0 d ays Of k et tles fromthe sam e fo undry .
,

cast under app arently the sam e co ndi ti ons one wi th i n the wri ter s exp er i ence ,
’

wi ll last onl y a month whi l e ano ther lasts over a year The life of a kettle i s ,
.

greatly prolonged if i t i s used excl usi vely for dezi nck i ng lead and has not to
, ,

serv e as i s the case i n m ost E uropean works bo th for desi lveri zi ng and refini ng , .

As by th e use of steama consi derab le am ount of ai r i s carr i ed i nto the lead

and c auses oxi da ti o n Roessl er
2
tri ed to replace i t by di fferent gases, Wi th .

C02 the lead bei ng heated to 700 C i n a shor t ti m e all the zi nc w

°
,
as conver ted

t o wh i te ZnO and co uld be ski m med ofl fromthe lead As CO; canno t be

,
.

easi ly ob tai ned p ur e to be used for such a p urpo se h e tr i ed a m i xture of C02 ,

and N o b tai ned by passi ng ai r through a cy li nder filled wi th glowi ng coal

,
.

The r e s ul t w as a gr ay powder i n w hi ch some of the zinc was present as metal ,

i n a finely di vi ded state By the use of a m i xture of CO and N draw n froma

.
,

g a s
-
pro d uc er a powd er of a d ark e ,
r gr ay w as ob tai ne d co n tai ni ng up t o 75 p er ,

cent of i ts zi nc as metal i n a finely di vi ded state the r est bei ng oxi di zed by the
.
,

C03 present Th e refined lead w . as enti r ely fr eed fromZn if the tem peratur e ,

‘
Bcrg . Z .
, 1 88 7, v r, 377 .

‘
Op . ci t .
, 1 890, x ux , 2 4 8 .
55 8 ME TALLURO Y OF LE AD

was kep t above 700 o therwi se a zinc cr ust formed on top of the lea d In
°
C ; . .

work i ng on a large scale wi th gas contai ni ng from 1 5 to 2 0 p er c ent of C02 .

,

too m any diffi c ul ti es wer e enco unter ed accord ing to Sch na b el

l
to m ak e th e , ,

process a p rac ti cal success .

One p rocess of refini ng desi lveri zed z i nc b eari ng lead m ay be m enti oned as -

i t has fo und favor i n som e E urop ean w orks I t i s the p rocess of F Roderbourg 2
. .

in w hi ch a mix ture of ZnClz and Pho i s sti rred i nto the kettle hold i ng the lea d .

The ac ti o n of th i s m i xture i s sai d to be

The sc umfloati ng on the lead bath i s rem oved a nd ,

tr eated wi th H 9O to r em ove the ZIl Clz The leached r esi due i s heated wi th
, .

N aCl and PbO and th er eby the ori gi nal r eagent prod uced
, The proce s s h as .

b een tri ed i n the Uni ted States and dropp ed .

2 53 M oldi ng of Refined Lead

.
— Th e moldi ng or casting of lead was form
erly do ne by h and b ei ng ladled fro mth e k et tl e i nto m
,
olds placed i n front of i t .

FI G .
58 2 .
—Lead -
moldi ng app aratus for refini ng furnace .

Thi s method ha b ecome obsolete At present the r efined lead i s run into m
s olds .

ei th er di rec tly fro mthe r ev erber atory f ur nac e or k et tl e i n whi ch the z inc had

been removed fromthe desi lver i zed lead or and thi s i s more com mon the re , , ,

fined lead i s tapped i nto a storage reverber atory furnace or a m arket ket tl e

fromwhi ch i t i s run i nto m olds .

In m ol di ng from the Refini ng Furnace a p i ece of 2 i n p i pe 6 p rovi d ed ,

-
.
, ,

wi th a stop cock a T jo int and a plug d Fig 582 i s scr ewed i nto a cast
-

,
-

, , .
,

i ron collar a fi t ted i nto the steel water j ack et at the tap ho le
, , To the - -
.

ver ti cal end of the T i s atta ched nipple c wi th elbow f at the lower end i nt o , , , , ,

whi ch i s screwed a lo ng pi pe g (from7 to 1 0 whi ch can be moved hori zo n ,

tally by arm h whi le i t di sch arges the lead i nto m

, , old s placed i n a half o r three
quar ters the center of whi ch li es beneath the ni pple The molds commonl y
, .

used now ( Fi gs 583 585) di fler fromthe ordi nary blast f urnace m
—
. olds i n tha t
one end r ests on tw o wheels 0 and the o th er has a leg 6 The li p of the m
, old , , .

above th e leg h as a hole 0 By passi ng a hook thro ugh i t and tilti ng th e m

,
. ol d
i t i s run away the bar ti pped out and the m
,

,
old then qui ckly r eturned to i ts ,

form er place At som

. e works th e m olds are made large eno ugh to hold thr ee
bars of lead The li p then has i nstead of the hole 6 a rec tangular socket
.
, , ,

r unning hori zontally i nto whi ch i s i nser ted a sli ghtlybent i ron handle to move
,

and tilt th e m old .

Schnabel -
Loui s ,
H andbook of Metall urgy , I, 54 7 .

Ger man P atent No . 2 4 1 4 83 ; M elall urgi e ,

1 9 2 , 1x , 2 39 .
1
 ME TALLURGY OF LE AD

for the moldi ng of lead ; Fi gs 589 59 1 hori zontal longi tudi nal and trans
.
, , ,

verse sec ti ons and Fi gs 59 2 594 detai ls of the 6 by 6 ft fireplace wi th

,
.
- -
.

step gr ate
-
.

The furnace 2 1 ft 9 in long and 1 2 ft 9 i n w

,
. ide has a m
. etal bath 3 ft . .
,
.

S IDE ELEVAT ION

FIG 586 .

ELEVAT IO N FLU E EN 0
FIG 587 .

Et s wmou BRl DG E W ALL END

I I G SSS
‘
-
.

FI GS .
586 t o 588 —
. E levati ons 1 00 -
ton storage ( moldi ng) reverberatory furnace
.

in. deep I ts general constr uc ti on i s simi lar to th at of a sof teni ng or r efi ni ng

.

f ur nace Being a storage or mo ldi ng f urnace i n whi ch the temperature i s k ep t

.
,

low the si des and ends are not water j acketed The steel pan holding the bri ck
,
.
 DESILVE RI ZATI ON OF L EAD B ULLI ON 561

work stands free on cross rai ls carri ed by longi tudi nal I beam
- -
s and i s heavi ly
,

i roned There are three doors to a si de and one end door

.
, Provi si on i s m
. ade

for using ry
an auxili a b urner The i nverted arch form
oil
-
. i ng the bo ttomrests
on concrete for a di stance of 3 ft on ei ther si de of the center li ne the rem ai ni ng
.
;
sp ace i s filled wi th red bri ck Th e walls of the furnac e are of fire bri ck
.
-
.

so
562 M E TALL URGY OF L E AD

The fireplac e, 59 594 Fi gs p gra te as. th e b i tumi nou

2—s coal , has a ste -

used is li gni ti c i n i ts ch arac ter that i s i t gi ves a long flam e and h as no eaki ng , ,

power whatever The fir eplace i s a 6 by 6 ft standard wh i ch serves also the

.
-
.

rever beratory f urnaces for smel ti ng drosses and ski m mi ngs ( Fi gs 6 2 7 .

and l i tharge ( Fi g s 63 1 .

m mmn s
' "

x3 3 o
'

aa xx
ng e x a x x x os

H ALF S ECTIO N HALF EN D

O N LI N E A . ELEVAT IO N
LONG ITU DINA L eecn ou ON LI NE 0 F10 S94
.

FIG S 59 2
. to 59 4 — Fi re p lace .
-
1 00 -
ton storage ( moldi ng) f
reverberatory urnace .

The mthod followed i n m

e oldi ng i s an adap tati on of the one used wi th cop
p er r efin i ng f ur na c es i n co nnec ti o n w i th th e Walk er c a sti ng ma ch i ne
1
I t was i n .

Op era ti o n i n 1 9 1 3 at the N ati o nal p lant of the Am er i can Sm el ti ng and Refi ni ng

Co So uth Chi cago

.
, and has si nc e been extended to o th er r efineri es
, Th e .

lead i s run fro mthe f urnace thro ugh a pi p e provi ded wi th regula ti ng cock , ,

i nto a cast iro n tro ugh whi ch sw

-
i ngs on tr unni ons A tro ugh i s a cyli nd r i ca l .

vessel 2 2 i n i n di ameter and 44 i n lo ng Op en at the top whi ch has five r i n

,
. .
, ,
-
.

p i pes servi ng as sp o uts Wh en ti lted forward by means of an ai r li ft the lea d

.
-

H of man , Cop per, 1 91 8 , 39 8 .

Pulsi fer, Mi n . E ng . World , 1 91 3 , xxx rx, 1 54 .

564 ME TALLURGY ’
OF L EAD

desi lveri zi ng Unti l recently the Stei tz si phon Fi g 562 w

. as used alm, os t .
,

excl usi v ely .

Tw o such m n i —
old g apparatus are shown i n F gs 595 598 In Fi gs 59 5
i . . .

and 596, 0 re resents the lo nger armof the si phon m ad of % i n p i p wi th

p e 1 e -

, .
,

the cast i ron stop

- -
lower end i t i s joi ned by two elbows wi th a
cock 6
, . At the ,

ni pple i nterv eni ng to the swi ngi ng pi pe b

, Th i s can be turned down aro und th e
-

,
.

center c and when i n that p o si ti o n i t can be moved i n a hor i zo ntal ci rcle havi ng
, ,

i ts c enter at d The si pho n i s filled j ust li ke the one shown i n Fi g 562 wi th th e

. .
,
 DE SILVE RI ZA TI ON OF LE AD B ULLI ON 565

excep ti on that the h l g i s do ne wi th

pi pe b i nstead of wi th a
and i n th e swi ngi ng -

, ,

pai r of to ngs As i n moldi ng the sw .i ngi ng pi pe has to descri be nearly a half ,

-

or three quarters ci rcle; the ordi nary way of keep i ng the si p hon i n place by
-

wei gh ti ng wi th a co uple of b ars Of lead i s not sufi ci ent For thi s purpose two .

i ron hoops about 2 ft 3 i n ap art pass around the bri ck w

,
ork of the kettle
. .
,
.

The tw o ends of a hoop are bent as shown i n Fi g 59 5 and t i ed by a bol t ,

.
,
.

The ver ti cal armof the si pho n a i s held i n place b etween the tw o hoop ends , ,
-

th e fixed bol t f and the m ovable one It , , , .

Ano th er arrangem ent for m oldi ng i s shown i n Fi gs 597 and 598 : i represents .

the long er armof th e si phon w i th the stop cock j ; i t di scharges the lead i nto a -

3
-
i h p
. i p e k close d at th e bo
, t to m , T h i s ha s tw o tr unn i o ns m wh i ch sw i ng i n .
, ,

the bear i ngs n They are joi ned to a pi vo t ro tati ng i n the sock et 0 The pi pe
, .
,
.
,

k i s co nnected w
, i th th e sw i ngi ng arm whi ch is m oved wi th the handle q , , ,

over the molds At some works the pi pe It has been replaced by a trough
.
, , .

At o th ers the bo t to mof pi pe k i s closed wi th a cap havi ng a sock et i nto whi ch , , ,

the pi vo t fastened to the floor fi ts loo sely

, Thus a num b er Of sli ght vari a ,
.

ti ons i n detai l are found at di flerent works .

The la test devi ce for m oldi ng lead froma kettle is the Mi ller Casti ng Ma
chi ne shown i n Fi gs 599 and 600 The lea di ng par ts are a ver ti cal cast i ron
l -
. .
,

mold wheel A wi th water j acketed molds B ; a stati onarycurved water j acket C

-

, , , ,

on the feed si de whi ch extends above the c enter Of the wh eel and fi ts snugly the
-

peri phery of the revolvi ng mold wheel ; a feed pi pe D i n the stati onary j acket - -

, , ,

to deli ver the lead i nto the m olds as they pass underneath ; and a shi eld E on , ,

the deli v ery si de to break the drop of the di scharg ed b ars as they fall on to a
,

car or co nveyor E ach m old has a recess i n the li p (not shown) for the exp ulsi on
.

of the ai r i nto the next mold and for recei vi ng af ter the escape of the ai r a sm all ,

am ount Of lead to serve as sam ple whi ch i s di scharged automati cally when the ,

bar drops fromthe m old The lead i s deli vered to the feed pi pe froma kettle .
-

by means of a Miller pump F the exces s flowi ng back i nto the kettle through a , ,

retumpi p e not show -

n The m ,
old wheel i s dri ven by a mo tor G maki ng 1 2 00
.
-

, ,

whi ch is geared to the shaft H of a w orm the wheel of whi ch , , ,

makes 4 and m eshi ng wi th the dri ve wh eel I causes thi s to m ak e -

, ,

r p m The m
. . . ac hi ne casts tons l ead p erh r wi th three m en; w i th a pum p .

deli veri ng froma central k et tle through a radi al trough seven m en are requi r ed

to do the work The m achi ne m ak es li t tl e dross as the deli v ery and return
.
,

l ead are not exp osed to the ai r; the bars are free fromdrosses ro ugh edges , ,

and shri nk hol es and hav e a uni formw -

ei gh t ,
.

2 54 Labor, Fuel , and Yi eld of Lead

.
— Wi th small plants havi ng 30 ton .
-

kettles i t has been c ustomary to gi ve i n contrac t the Operati o ns of sof teni ng

, ,

desil v eriz i ng and refini ng Wi th large uni ts of 60 and 1 00 ton k ettles thi s
, .
-

has b eco m e im prac ti cable Therefore each Operati o n has i ts separate men who .

have to carry thro ugh thei r task s i n a gi ven time Thus sof teni ng i s plac ed .
,

on a 2 4 hr b asi s desil v eri z i ng and r efini ng each on an 8 hr b asi s

-
.
,
Molding -
. .

and lo adi ng of lead i s usual ly do ne by a se ar ate cr ew i n co ntr ac t

p .

1
U S Patent No
. . . 1 1 57794 , Oct . 2 6, 1 9 1 5; E ng . Mi n . J .
, 1 91 6, on, 662 .
566 M E TALLURGY OF LE AD

The fuel consumed i n sof teni ng desi lveriz i ng and refini ng used t o be 1 3 0 , ,

lb p er ton of lead b ulli on ; this figure has been reduced to 50 lb

. .

The am o unt of lead recovered i n the formof market lead vari es wi t h the
pur i ty of the lead bulli on I t used to be 80 p er cent of the bulli on ch a rged . .
,

when th i s had not been caref ull y drossed before i t reached the refinery W i th .

dro ss fr ee b ul li on and th e i m
-

p rov e m e nts m ad e w i t h t h e proc ess t h e y i e l d i n ,

market lead at present i s usually 90 p er cent of the lead b ulli on

2 55 Treatm
. .

. ent of Zi nc Crust, General

1 —
Many methods have been tri ed .

and used for th e tr eatm ent Of z i nc cr usts The only one whi ch has s urvi v ed .

i s di sti llati o n whi ch ori gi nated wi th Park es,

.

Sm el ti ng i n th e blast f ur nac e ( Flach process) wi th slag h i gh in Fe so m e ,

matte and flux and a lowpressure blast furni shes qui ckly a ri ch lead bull i o n
,
-

but sacr ifi ces the z i nc and i s accom pani ed by large lo sses i n si lver and l ea d ,
.

Cupellati on of the cr ust i s m ore cr ude th an smelti ng i n the b last f urna ce .

Fusi on wi th alk ali chlori des wi th th e idea of conver ti ng the zi nc into sol uble
chlori de was a fai lure 2
.

Treatm mt Of par tly li quated crust wi th steami n a kettle at an eleva ted

tem p e r at u r e w i th th e ai m Of
,
o x i di z i ng th e z i n c ( a n d i nc i den ta lly s o m e le a d )
and th us O b tai ni ng a r i ch bulli o n and a m i x ture of lead and zi nc oxides h as ,

been i n oper ati on i n several E uropean plants The ri ch lead used to be .

c upell ed and the oxi de mi x tur e added gradually to the charge Later Schna bel
,
.

leached the oxi des wi th am moni um carbonate precip i tated any Cu present ,

wi th Zn fil tered the soluti on recovered the z i nc fromi t by boi li ng wi th steamas

, ,

a basi c carbonate w hi ch af ter calci nati on gi ves a zi nc wh i te wi th a shade of yel , ,

low and cupelled the ri ch lead addi ng the lead r esi due freed fromZn t o th e
, , , ,

ch arge The process was i n oper ati on at several E uropean plants but h as
.
8
,

become o bsolete .

2 56 Di stillati on of Zi nc Crust, General

.
t — Thi s proc ess first used by .
,

Parkes has undergone m,

any i m provements and has become the one uni ver
sally used si nce Balbach fir st used gr aph i te r etorts
Ii
The m ethod th erefor e .
, ,

of ten bears h i s name Retor ti ng i n vac uo has been suggested whi ch wo uld
6
.
,

permi t carryi ng out th e process at a much lower temperature than i s th e case

under atm ospheri c pressure ; but so far i t i s merely a suggesti on .

A furnace to be sui ted for the p rocess m ,

ust per m i t the rai si ng and sustai ni ng ,

of a hi gh tem p e r atu r e a n d a t th e s a m e t i m e b e of s uch a co ns t r u

,c t i on th a t a

1
Kerl, B .
, Grundri ss der Metall h uttenkunde, Feli x, Lei p si c ,
1 88 1 , 3 1 4 .

Roswag, Désargentati on de p lo mb, D unod, Pari s,

”
1 884 , 2 96 .

“
Sch nabel, C Loui s, H , H andbook of Metallurgy,
.
-
”
. Macmi ll an, Lo ndon ,
1 90 5, I , 6 64 .

Zeiller H enry, Ann -

. Mi n .
,
8 70 , xvrr, 44 7 ; B erg H atten
1 . mZ. .
,
1 8 71 , xxx , 4 2 2 .

D eta ils : Schnabel— Loui s ,

op ci t , 6 79
. . .

W orks ci ted in § 2 44 .

E ilers, Tr A I 75,
. . . M . E .
,
1 8 74 — I II , 31 4 .

Roesi ng, Z t B erg H i ctten S al W i Pr , 886, B H at Z 886,

' ‘

. . . . . . . 1 xxx rv, 9 1 ; erg ten

.rn . .
, 1

X LV, 4 2 1 .

lI E uri ch, Tr A I . . .M E 1 9 1 2 X LIV

. .
, , , 74 1 .

Turner, J . I nst . M et , 1 9 1 2 VII , 1 05

.
,
.
568 ME TALL URGY OF L EAD

FIG 601
. FI G 602
.

FIG 603
.

FIG 60$
.

FIGS 60 1 to 605 — Faber du Faur retorti ng f urnace,

. . co ke fired
-
.
 DE SI LVERI ZATI ON OF LEAD B ULL I ON

were very thi ck at the bo t tom; at present they are made of grap hi te to whi ch
sufi ci ent clay (4 5 p er cent ) has b een added to gi ve strengt h and st abi li ty to .

the retort A 1 000 lb retort i s 36 i n hi gh 8 i n wi de at the neck 1 8 in at t he

.
-
. .
, .
, .

belly and 1 3 i n at the bo ttom I t i s 1 % i n thi ck at th e neck and i ncreases to

, . . .
,

2 i n at the bo t to m
. A so call ed 1 500 lb retort i s show n i n Fi g 606
. It is - -
. . .

advi sab le however to ch arge not m , ore than 1 300 lb , .

A set of retor ti ng furnaces i s arranged i n tw o ways They are ei ther plac ed .

o n bo th si des of a hori zo ntal fine i n such a w ay th at the openi ngs i nto i t shall

not be Opposi t e each o th er or th ey are b ui l t say , ,

ei gh t aro und a c ent ral stack each flue extend i ng

, ,

i nto the stack and then conti nui ng upward for a

fewfeet Wi th both arrangements obstruc ti ons of
.

t he draf t are avo i ded .

2 The Oil fired Furnacefi A m

.
— odern f urnace
-

—
wi th ful l detai ls i s shown i n Fi gs 60 7 61 2 Agai n . .

th ere i s seen a cast i ron fram e work swi ngi ng fro m -

t runni ons but li ned w i th 9 i n fire bri ck at th e

, .
-

si d es and 4 % i n at fro nt and back I t i s fired w

. i th .

Oi l fro ma Bill o wLong flam e Bur ner Class F R ’ -

, ,

represented in elevati on and secti on i n Fi g 61 3 . .

Thi s i s a br ass cham ber Oil burner 1 2 i n long

s
,
-

,
.
,

wi th central Oil com p a r t ment pro v i de d w i th a

needle valve and enclo sed by the ai r di vi si on

-
.

The cham ber has fixed vanes to effec t an i nti mate

mi xture Of atomi zed Oi l and ai r; the outlet nozzle
is i n i n di am eter Oil i s held at a pressure of
. .

FI G 606 — Grap hi te retort

1 0 lb p er sq ln and ai r at one lb
. .
,
. . .
,
.

capaci ty 1 500 lb charge

The retort i s 3 ft 2 % i n long and 2 2 % i n i n
. .

. . .

di am et er at the b ell y ; the w alls are 3 i n th i ck at th e bo t to mand taper to 2 .

i n at the neck
. The vessel holds 1 3 50 lb crust m
. i xed w i th a li ttle charco al ; .

i t rests on a fire bri ck block I t wi ll be no ti ced Fi g s 609 and 61 0 th at the

-
.
,
.
,

retor t i s placed i n beyond the center li ne of th e furnace i n order th at the .

heati ng space near the burner may be larger than the one opposi te and th ereby ,

the di st ri b uti on of hea t m ade even The correc t placi ng of the retor t i s of .

greatest i mportance as regards li fe of vessel and result of di sti llati on Fi g . .

60 7 show s i n do tted l i nes the c ast i ron condenser h eld i n pl ac e by a chai n -

suspended fro mt w o books ( Fi gs 60 7 608 At the front of the f urnace .

, , ,

Fi gs 60 7 and 608 next to the floor are tw

. o sq uare openi ngs for tappi ng any
, ,

lead that may have escaped froma leaki ng retor t .

2 58 Condensers —
. The condensers used for coll ec ti ng the zi nc difl er very
.

much in formand materi al Some are si mply old retorts ; others are plumbago .

I
A drawi ng of the oil fired furnace -
at M aurer, N J , has been p ublished i n E ng Mi n J
. . . . .
,

1 90 7, L X I II , 84 X X .

’
N ati onal Sup ply Co , 4 1 6 W est Grand Ave , Chi cago Ill .

m
. .

H of an, General Metallurgy, 1 9 1 8, 336

”
.
570 ME TALLURGY OF LEAD

cruci bles (di ameter at bo ttom 7 i n ; at top 1 1 i n ; hei gh t at front 1 8 i h ;

,
.
,
.
,
.

at back 2 2 i n ; thi ck ness 1

,
.
,
Again th ey are m
, ade of cast i ro n havi ng

the formof a t r uncated co ne One condenser of thi s class i s 2 ft long and h as

. .
,

handles on ei ther si de by whi ch i t i s susp ended on two hooks fro mth e i ro n frame
Of t he f urnac e
. A coni cal condenser i s also m ade O f clay ; i t i s abo ut 3 ft lo ng
.

and suppor ted by a tri pod Ano ther form i s that of a sheet i ron cyli nder
.
-
572 M E TALL URGY OF LEAD

li ned wi th speci ally molded fire bri cks At the base i t has in addi ti on to the
-
.
,

tappi ng hole t w
-
o sm
,
all pi vo ts to hol d a t hi n chai n whi ch is hoo ked to the frame

of the furnac e th us supporti ng the condenser It i s clai med by so me refiners

, .

that an i ron cond enser furni she s a larger yi eld i n zi nc than one m ade of clay .

FIG 620
.

FIG 621
.

FI GS 6 1 9 to 6 2 I —Si n le i ece cast i ron condenser

g p
- -
. . .

FIGS 6 2 2
. and 6 2 3 — Truck
. and stand for condenser .

In Fi gs .
—
61 4 6 1 8 are gi ven the detai ls of the t wo pi ece cast i ron condenser
- -

i ndi ca ted by li nes i n Fi g 60 7 It has a pec uli ar formwhi ch i s the

do tt ed . .

result of exp eri mentati on It i s made up of two pi eces bol ted together
.
,

the lower b ei ng heavi er than the upper ; there are handles on the si des a I M i n ,
-
.
 DE SILVE RI ZA TI ON OF LE AD B ULLI ON 573

tap -
hole and a I M i n port for the passage of gases and fumes At one plant
,
-
. .

t h e lower part i s of cast steel The m anner of support has been gi v en already . .

Fi gs 6 1 9 62 1 show ano ther condenser of formsi m

— . i lar to the one gi ven i n
Fi gs 6 1 4 6 1 8 but of m
.
— ore si m ple constructi on It i s a si ngle pi ece casting
, .
-

wi th handl es on the si des the usual tap hole but no port for the escape Of ,
-

g a se s Th e .co n d e n s er i s ca rri ed by a t r uck s ta n d of fl a t i ro n gi v e n i n F i gs 6 2 2 -

.

and 62 3 The front vi ew Fi g 62 3 shows the curved suppo rt for the condenser ;
.
, .
,

th e si de vi ew Fi g 62 2 presents a horizo ntal t ray whi ch carri e

-

, .
, s the m old i nto
whi ch i s tapped the condensed zi nc .

The co ndensed zi nc i s rarely allowed to run ofl conti nuo usly Usually .

t h ere i s a tap hole cl osed by a clay pl ug or a coni cal pi ec e of coke and the
-

condensed zi nc i s di scharged i nto a sui table mold i n 3 or 4 hr af ter the .

di sti llati on begins It has been found that more zi nc wi ll collect i n the con .

d enser i f thi s contai ns some li q ui d zi nc M ost condensers have a second .

O peni ng on the upper si de for f um es to pass thro ugh whi le the d i still ati o n i s

goi ng on They go i nto a sh eet i ron pi pe leadi ng to the m

. ai n flue It has
-
.

always been consi dered essenti al to have thi s second openi ng i f th e di sti ll ati on

i s to proceed i n a sati sfac tory w ay; but at som e works usi ng an old retor t as

co ndenser th e second openi ng has been di spensed wi th the condenser b ei ng p ut ,

i n plac e only wh en the di sti llati on b egi ns and not as i s c usto m ary wh en th e , , ,

retort i s well filled .

2 59 The M ethod of W orki ng

.
— The m ethod of worki ng i s abo ut the sam e

whi chever furnace i s used Wh en a newretor t has been p ut i n place i t i s .

,

car efully warmed by burning i n i t for 2 4 hr slabs of wood and brough t to

.

.
,

a d ull red h eat I t i s th en r eady for the oil bur ner and for chargi ng
. The -
.

z i nc crust m i xed w i th from1 to 3 p er cent of ch arcoal i s bro ugh t i n an i ron

,
.
,

wh eelbarrow or car to the front of th e retor t and charged wi th a trough shaped -

The tem
°
scoop . perature i s then q ui ckly rai sed to about 1 2 00 C the crust .

sof tens and si nk s i n th e r etor t af ter h alf an ho ur i s p ush ed dow n m ore crust , ,

i s added and thi s i s r epeated ti ll the retor t i s w ell fill ed

, The upper ri mOf .

the co ndenser rec ei v es a h eavy l ute of cl ay i s passed ov er the neck of the ,

retort and is made to adhere to the front wall of the furnace; i t i s suspended
,

or rests on i ts suppor t About an ho ur af ter chargi ng blue powder and .

,

then m etalli c z i nc begi n to coll ec t i n the condenser .

At atm I n la boratory experi m

°
ospheri c pressure zi nc boi ls at 9 1 8 C 1
ents .

for the recovery of zi nc fromcyanide pr eci pi tate Clevenger fo und that at 1 2 00 ’ °

,

C th ere w as exp ell ed 90 p er cent and at 1 2 96 C as m

°
. uch as p e r c en .t of . .

the zi nc pr esent ; also th at i t w as i m p or t an t to r a i se th e t em p e r at u r e q u i c kly

and to k eep i t co nstant wh en i t had at tai ned i ts proper hei gh t .

The zi nc v apor carri es over w i th i t som e l ead if the tem perature i s too hi gh .

J u r et z ka
a
i n di sti lli n g i m p
, ur e z i nc fo u n d th a t a t 1 000 C so me l ea d w a s ca rr i,
e d °
.

over and that at 1 1 00 C the co ndensed zi nc vapor contai ned

,
°
.
p e r c e n t P b . .

I
Berthelot, Co pt rend , 1 90 2 , ourn , 70 5 m m
m
. .

Tr A I M E , 1 904 , xxx rv, 89 1 ; E ng Mi n J

. . . . . . . .
, 1 9 1 4 , x cv , 1 09 .

Che mZ . .
, 1 91 6, X L, 885, 894 .
 ME TALLURGY OF LEAD

I n di stilli ng c si lver alloy Rose exper i enced losses in Ag averaging

zin -

,
I

p e r c en t ; F ri edri ch 2
fo. und lo sses to r ang e fro m to p er c ent A g t h e .

losses i ncreasi ng wi th the q uanti ty of zi nc and the temperature In work i ng

,

zi nc si lv er lead cr usts
-
the large am
-
ount of Pb and the sm all percent age o f ,

Zn change condi ti ons Som e Ag passes over wi th the Zn ; the collected z i n c .

assays from 4 to 1 2 oz Ag p er t on depend i ng upon the r ate of di sti ll ati o n . .

Wi th 8000 oz retort bulli on the collec ted zi nc has shown assays as hi gh as 2 4 o z

-
. .

Ag p er ton; ordi narily a 1 200 lb charge gi ves zi nc wi th from4 to 5 oz A g -

. .

p er ton .

Thework of Rose
c go ld alloys shows that the lo ss 3
and Fri edri ch ‘
wi th zi n -

exp er i enc ed i s ch i efly m ech ani cal .

The beh avi or of telluri um whi ch readi ly enters the zi nc cr ust i n desilveri z
5
,

i ng i s of i nter est as long as tel uri de gold ores are treated by lead sm el ters
'

,
.
,

Table 1 4 1 gi ves som e analy ti cal data of the prod uc ts ob tai ned i n r etor ti n g

telluri umbeari ng zi nc crusts from Pertulosa I taly

-
The three succe s si v e , .

zi nc taps wi th th ei r i ncr easi ng percentage of Te show th at Te i s not as easi l y

, ,

TAB LE 1 41 — . D I STI LLATI O N or ZI NC CRU S T CO N T AI N I N G T E LLU RI U M

Products Te ( a) Se

Fi rst zi nc tap . 0 0030

Second zi nc tap 0 0050 .

Thi rd zi nc tap . . 0 01 .
50

Ski n of zi nc, li n 0 03 70 .

i ng condenser
Zi nc 0 4 090 ( a) 6 7 . 0 2 40

Blue po wder .

Retort bull i on . .

Gas from con

denser

Products N i , Co

Fi rst z i nc ta p
Second zi nc tap
T hi rd z i nc tap
Ski n of z i nc, li ni ng condenser
Zi nc telluri de
Blue po wder
Retort bulli on ( a) 88 89 74
Gas fromcondenser .

( a) B y di fference . ( b) Volumes .

I
Tr I nst . . Mi n M et . .
,
1 904
-

05, xxv, 394 .

I
M etallurgi e ,
1 90 8, v, 593 .

I Loc . ci t .
, 39 2 .

Zt . ango w Chem . .
,
1 90 3 , 2 69 .

I
H eberlei n, Berg H atten . mZ . .
, 1 89 5, LN , 41 ; Mi n I nd .
, 1 89 5, I V, 4 80.
576 M E TALLURGY OF LEAD

FIG 626
.

Fro 625
. S IDE ELEVAT ION

FI GS . 6 2 4 to 6 2 6 — Tilti ng pot for retort bulli on

. .
 DE S ILVE RI ZA TI ON OF LE AD B ULLI ON 577

At many work wi th the retort bulli on i s rai sed fro mi ts supports by

s, the p ot
means of an overhead crane a traveli ng ai r li ft or a di fierenti al pulley trans ,
-

, ,

ferred to the cupelli ng furnace and i ts content poured i nto the furnace thus , ,

doi ng away wi t h dro ssi ng m oldi ng etc Thi s mode of operati ng was started i n , , .

1 90 1 by F B F Rh odes at the N ati onal Works i n South Chi cago

. . . The ,

resi due i n the retort consi sti ng of slag and charcoal i s removed wi th an i ron , ,

scraper I t i s essenti al for th e li f e of the retort that i t be well cleaned af ter each
.

disti llati on The retort i s nowrai sed and som . e fine charcoal thro w n i nto i t to ,

prevent the oxi dati on Of the globules of lead adh eri ng to the si des ; i t i s then
t urned b ack to i ts norm al po si ti on and i s ready to be ch arged agai n Wi th a ,
.

coke fired furnace the grate bars are cleaned cli nk ers adheri ng to the furnace
-

walls or si des of the retor t are removed and fresh coke i s added maki ng the fur , ,

nace ready for th e next ch arge The ti m e requi red for di schargi ng and refilli ng .

i s abo ut 2 0 m in In scrapi ng care m ust be taken t o do i t gently so as not to

.
, ,

wear Off the lower si de of the retort To avoi d thi s as well as to change the .
,

li ne of contac t wi th the surface of th e lead the po si ti on of the retort i s so m e ,

ti m es chang ed af ter i t has worked abo ut 2 5 charges by t urni ng i t

, ,

The tools req ui red by one m an i n retor ti ng are : t w o scrapers ( 6 ft long .

,

in ro und i ron flat tened out at one end to the wi dth of 3 i n and b ent up 3
-
. .

i n ) to sti r the co ntents of the retor t af ter di sti lli ng and to rake out the resi d ue
.

af ter ti lti ng ; tw o pok ers ( 5 ft lo ng of i n i ron) to rem ove the cli nkers from .
,
-
.

the grate ; one bar ( 8 ft lo ng i n steel) to break 06 cli nk ers fromthe walls ; .
,
-
.

one sc oop to feed the cok e; one ladl e ( 6 i n i n di am eter and 3 i n deep w i th a . .
,

4
-
ft h a n dl.e); t w o s la g po ts li ne d wi th bri ck ; a wh ee lba rrow to r ec ei ve
-
th e zi n c
crust ; one scoop and shovel to ch arge the retort ; two molds for each retort to
recei ve the zi nc ; I o bulli on molds .

Am ethod Of doi ng away wi th the usual proc edure Of retor ti ng has been sug

gested by Roesi ng 2
I t i s to m elt the crust i n a basi c li ned r etor t to ch arge
.
-

so m e f uel for t he exp ul si o n of ai r and to po ur i n m elted p i g i ro n Thi s i s to , .

volatili ze the zinc whi ch i s collected i n a condenser ; then the p i g i ron i s poured
Ofl to be used agai n and followed by the retor t b ulli on
"
.
, ,

2 60 Results — The wei ght Of the charge i s from1 000 to 1 300 lb of zi nc

. .

crust and i t tak es from 6 to 8 hr for one operati on; less ti me i s requi red
, .

i n wi nter t han i n sum mer The crust yi elds from70 to 80 per cent of Pb con . .

tai ni ng fro m4 to 1 0 p er cent of Ag and from 5 to p er c en t of Z n . . .

The zi nc recovered i n the for mof m etal i s abo ut 1 0 p er cent of the wei gh t of .

the crus t and that i n the formof blue powder about 1 p er cent
,
Of all the zi nc .

requi red for desi lveri zi ng over 60 p er cent used to be recovered to be used agai n ,
.

i n the k ettles Thi s has b een rai sed to 80 p er c ent by the use Of the H ow
. ard .

sti rr er and pr ess and by Oil hri ng The quanti ty of dross vari es a great deal ;
,
-
.

from5 to 8 p er cent Of the wei gh t of the crust was a fai r figure before the H ow .
,

ard i m provements The blue powder formed am o unts to fro m 1 2 to 1 8 lb

. .

p er ch a rge T h e a dd i ti o n of 1 lb
. s al t a n d 4 lb sa n d to a 1 2 00 lb ch arg e i s . .
-
.

E nri ch Tr A I M E 1 9 1 2 X LIV 750

I
,
. . . . .
, , ,
.

I
B erg H uttenrn Z. . .
,
1 890, x ux , 369 .

37
578 ME TALLURGY OF L E AD

sai d reduce the amount from1 8 to 1 2 lb The blue powder i s ei ther retu rned
to .

to the r etor t or sold to zi nc w

,
orks after screeni ng .

TAB LE 1 42 .
-
DI S TI LLATI O N or ZI N C CRU ST

Zi nc crust . 2 7 00 64 4
Reto rt m
et al 1 67 1 I .
5
Bl ue p o wder . 82 6 . 2

Sl ag 54 8

Zi nc cru st . 2 55 1

Ret ort m
et al 1 659 2 .
3
Blue p o wder . 84 85 5 .

Sla g 1 94 so 9 2 2 9
. .

Zi nc 1 01 5 70 3
Retort m tal
e 73 0 o 9 .

Blue p o wder 5 3 s .

Slag 99 6 1 s . 0 -
33

Zi nc 2 5 80 67 7 21 .
5
Ret ort m
et al 1 803

Blue p o wder .
7
S lag 2 44 12 5

Zi nc 2 3 44

Ret ort m
et al 1 4 03

Blue p o wder . 14

Slag 6 86

In Table 1 4 2 gi ven results Ob tai ned i n worki ng crusts free fromi mp ur

are

i ti es, and crusts wi th varyi ng amo unts of Sb As and Cu Col um n 1 gi ve

s t he , , .

concentrati on of si lver i n lead effec ted by the Parkes process ; i t i s seen to range
from9 to 30 per cent and i s usually near 30 per cent The recovery of zi nc i s
. .

seen to cover the wi de range of 60 to 89 p er cent ; a co m mon figure is 80 p er cent . .

The hi gh zi nc content of the slag ( dross) 1 2 5 to

-

p e r c en t show s th e di rce ,
. .
,

ti on i n whi ch li es a consi derable loss of zi nc In worki ng off the slag ( dross) .

i n the c upel the hi gh zi nc content of the charged m

, ateri al i s very app arent
-
.

The sl ag ( dross) also shows hi gh val ues i n doré New t on calls attenti on to
I
.

the efl ect that Cu som eti mes has i n form i ng w i th low di stillati on tem peratures , ,

l um ps whi ch assay as hi gh as oz Ag ( Au) p er ton when the retort bul .

,

li on has a val ue of 3000 oz Blakem ore em

z
phasi zes the effect Cu has on the
.

presence of Au i n dross .

The i m puri ti es Sb As and Cu seemto be evenly di stri buted i n crust and

, ,

retort metal but appear only as traces i n the blue powder

, .

A retort lasts now40 ch arges ; form erly 2 5 charges w as consi dered a good

average For every ton of crust 1 1 00 lb of coke or 4 0 to 60 and ev en 70 gal Oi l

.
, . .
,

wi th ai r as atom i zer are req ui red To use a good q uali ty of coke of uni form
,
.

I
Tr A I
. . . M 5, . E .
,
1 91 LI , 79 1 .

I
Tr
. Austral I nsti t Mi n E ng ,
. . . . 1 898, v, 247 .
580 M E TALLURGY OF LEAD

the ski m mi ng and to collec t the Cu in a matte Thi s i s accompli sh ed by

, .

sm el ti ng i n a w ater j acketed r everberatory f ur nace wi th the addi ti o n of h i gh

-

grade galena ( 80 p er cent Pb) The metalli c lead whi ch had been wi th d rawn . .

fromthe softeni ng furnace as well as the lead reduced fromthe ski m mi ng by

galena and fine coal spread over the charge wi ll collec t on the bo ttomo f th e ,

hear th I t wi ll contai n nearly all the p reci o us metal of the ski mmi ng as th e
.
,

finely di vi ded globules of r educed lead passi ng downward t hro ugh the ch arge
w l c ry wi th th the preci o s metal as s the case i n cr c b e s ver as say
i l ar e m u i u i l il —
,
.

On top of the lead w ill float the m ol ten ski m mi ng freed frommetalli c lead and
preci ous metal The r esulti ng lead b ulli on whi ch has taken up about 1 5 p er
.
,
.

cent Sb goes to the sof teni ng f urnace The mat te contai ni ng Cu 2 5 Pb 55

.
, .
, , ,

S 55 and Sb abo ut 1 5 p er c ent i s treated by a conc entra ti on sm . .

, el t i ng proc -

ess or goes to the conver ter to be blown to bli ster copper The r efined .

ski m mi ng wi th 1 5 2 0 p er cent Sb some As

— c A
p er e nt C u
. a n d 1 I , o z g , .
,
-

_ .

p e r t o n go e s to th e h a r d le a d b l a st f ur n a c e -
.

In a sm all r ev erberatory fur nace 1 0 ft 6 i n by 9 ft 6 i n wi th fire bo x ,

. . . .
-

4 f.t by 4 ft 6 i n s
. e r v e d by . u
,
n d e rg ra te bl a s t ch arg es w e i gh i n g 6 35 lb (35 0 l b ,
. .

dross 1 50 ski m
, mi ngs 1 00 galena 2 0 sand 1 5 fine coke) are dropped fromth e
, , , ,

hopper i n the roof i n q ui ck successi on unti l th e hear th i s filled and th en rep len ,

i shed as fast as th ey m el t so th at th e f usi o n tak es place on a bath of l ea d

, Th e .

surplus of l ead i s ladl ed out fro mthe well ; sp ei ss m at te and sk i m ming are , ,

tapp ed i nto an ov erflow slag p ot In 2 4 hr 90 charges are work ed y i eldi ng

-
. .
,

lb of lead bulli on a sm
. all am o unt of sp ei ss ( Cu 50 Pb 1 7 p er cent Ag
, ,
.
,

1 1 7 and Au 2 5 6 oz p er to n ) 35 00 . l b m a t t e ( C u 35 to 4 0
, P b 3 p
0 e r c e n t . A g ,
.
,

1 00 and Au oz p er ton) and 5000 lb cl ean ski m

. mi ng ( Pb 75 p er cent Ag
,
. .
,

1 to 1 5 6 oz p e r t.on ) T h e r eas o n th a t. su ch a larg e a m o u nt of m a t e r i al c a n b e

sm el ted i n a com parati vely sm all f urnac e i s th at i t i s tr ea ted on a b ath of lea d ,

and th at the f ur nac e never b eco m es coo l The b ulli on goes back to the soften .

i ng f ur nace The m. atte i s sm el ted i n a cup elli ng f ur nac e w i th so m e si li c i o us

materi al i nto copper bo ttoms 60 p er cent Copper matte and slag the bo t toms ,
-
.
, ,

collec ti ng the gold The f ur nace i s similar to the one rep resented i n Fi gs
. .

8 8 — T h e t es t r i n g wh i ch i n o t w a t er j a ck et ed i s 6 by 8 ft a n d i li n d
3 39 2 s s e
- -
.
,
.
, ,

wi th a mi xture of rawand bur ned clay ; the cavi ty is 6 i n deep The slag runs . .

O fi fro mthe fro nt i nto an i ro n p o t and wh en the test i s f ull of m etal and m atte , ,

the co ntents are tapped i nto m olds placed on a tr uck beneath the test by , ,

dri l li ng wi th an aug ur a hole i nto the breast The tap hol e i s agai n clo sed from .
-

the i nsi de by i nser ti ng a clay stopper at th e back through the tuye re hole ; the -

f urnace i s then ready for ano th er charge When the mo lds are cold the .
,

bo tto m s are separated from the m atte The m at te i s bro ugh t forwar d i n .

ano th er c up ell i ng f ur nace to m etac copper to be used i n p reci p i tati ng si lver

fro m si lver sulphate soluti on Ob tai ned i n par ti ng doré si lver by means of ,

sulp h ur i c aci d For ev ery 1 00 lb m

. etalli c copp er prod uced 2 6 gal of r educed .
, .

oil are r eq ui red an ai r i nj ec tor b ei ng used

,
-
.

A large furnace for doi ng sim i lar work i s shown i n Fi gs 6 2 7 630 — I ts lead . .

i ng fea tur es are si m i lar to those of the sof teni ng fur na ce gi ven i n Fi gs 51 7 524 .
-

.
 DE S I LVE RI ZA TI ON OF LEAD B ULLI ON 58 1

The fir eplace i s the sa me as th e one . 2

—
i ll ust rated i n Fi gs 59 594 The f ur nac e
.

r ests on steel rai ls carri ed by m

longi t udi nal I bea s, i s heavi ly i roned, and water
-

j acketed at si des and ends . I t has at one si de, the firebri dge end, a lead well
-

1 11 91 1 1 1 0

wi th hole and at th e o th er a tap hole for matte and sk i mmi ng ; at th e flue

tap -

,
-

end i s ano th er tap ho le for em t yi ng th f u n c Th h r th i ft i n

‘

p
-
e r a e e ea s 1 5 .
9 . .

by 7 ft 9 i n and 2 ft 3 i n deep correspondi ng to 2 75 cu ft and a cap ac i ty

. . . .
,
. .
,
582 M E TALLURGY OF L EAD

for about 1 80 tons molten lead The mode of operati ng is the same as w i th the .

sm aller fur nac e ; the am o unt of materi al treated i s about 2 5 p er cent gr ea ter . .

At the works of the Internati onal Lead R efini ng Co E ast Ch i cago Ind .
, ,
.
,

sti b ni te ( s sa) i s fr eq uently used as r educ i ng agent i ns tead of galena ( PbS ) .

A charge i s m ade up of sof t ening fur nac e dro ss and sk i m mi ng li tharge and -

, ,

sti b ni te ; i t f ur ni sh es lead b ulli o n (Pb 94 to 9 5 Sb 3 to 4 Cu p er c ent , ,

.

Ag and Au 2 00 to 2 50 oz .
p er ton) , matt e ( Pb 50 to 55,
Sb to As 1 ,

Cu 30 to 3 5 p er ; Ag 1 00 to I 50 acent
n d A u . o
-
z p er ton ), and r efin e d .

mm
sk i i ng ( Pb 4 5, Sb 2 0, As I to 3, Cu 5, S i 02 6 p er c ent ; A g o z p er . .

ton, Au no ne) I t i s surpri si ng th at th e lead b ulli on does not run hi gher i n

.

Sb than th at produc ed wi th galena as a reduci ng agent .

S mall
r f urnaces wi th hear ths 8 by 1 2 ft and 1 0 i n deep and not p rovi ded
e , . .

wi th lead well someti mes have a tap pi ng slo t wi th two tap holes th e lower
-

,
- -

for lead and th e upper for refined sk i m mi ng the lead to be coll ected i n a k et tle ,

and the sk i m mi ng in slag po ts Other f urnaces of si mi lar si ze have a si ngle tap

-
.

hole; the enti re co ntent Of the f ur nace is tap ped i nto a kettle wi th overfl ow
spo ut Whi le the lead i s flowi ng i nto the ket tle part of i t i s ladled i nto mol ds
.
,

if nec essary When the lead has run out and th e ski mmi ng ap pears i t wi ll
.
, ,

collec t on the lead i n the k ettle and overflow i nto slag p o ts p laced benea th -

the spout Af ter th e m

. olten charge i n the furnace has run out the tap hol e ,
-

i s p l ugged and newm , ater i al fed i nt o th e f ur nac e The sk i m mi ng floati ng on .

th e lead i n the k ett le hardens i n a shor t ti m e i s r ai sed to dr ai n O fl adh eri ng ,

lead and then removed The lead i n th e ket tle i s cast i nto bars and goes t o
,
.

the sof teni ng f ur nace When cak es of li quated ski m

. ming are rolled out from
the slag p o ts and brok en th er e wi ll be fo und tw
-
o produc ts : li quated ski m
, mi ng
assayi ng under 3 oz Ag p er ton for m i ng the b ulk of the co ne and at th e bot
.
, ,

toma sm all c ak e of a Sil v ery wh i te an ti m o ni al sp ei ss of Pb and Cu wh i ch con ,

tai ns as m uch as 40 p er c ent Cu and wi th 2 50 oz b ulli o n assay s of ten as h i gh .

,
-
.
,

as 300 oz Ag p er ton . Analyses of anti m oni al sp ei ss are gi ven i n Table 1 4 3

. .

T AB LE 1 43 .
-
AN ALYS E S or AN I I II O NI AL SPE I ss
' ' I

Ano th er sa mple gave Pb p er cent . and Sb p er cent .

, th e anti moni a l
lead prod uced assayi ng Sb 1 8 p er cent The spei ss has a beautiful amethysti ne .

color shows cleavage planes simi lar to those of spi egeleisen and i s sec ti le
, ,
.

For m erly i t w as co nsi der ed p r ef erable to tap th e sk i mmi ng or let i t Over

flow on an i ron plate as i t ch i lled qui ckly and was easi ly broken to p i eces
, ,

but i t ran h i gh er i n silver .

I
Sa m p le f ro mA W J enk s ; analyses by F H D avi s
. . . . .
584 ME TALLURG Y OF L E AD

ente s r hard lead on bei ng smelted The dro ss fro mli q uati ng the crude
the .

hard lead has been found to contai n as much as 40 p er cent Cu but generall y .
,

co ntains abo ut 1 0 per cent The hard lead i s usually molded by l adli ng from .

the k et tle i n whi ch i t has been poled or fromthe one i nto w hi ch i t ran fro mthe ,

li quati ng furnace H ard lead bars wei gh 73 lb

. The surface of the refined .

hard lead when li q ui d soon becom

, es cover ed wi t h dross and i n order to
, ,

Ob tai n clean bars wi tho ut bei ng forc ed to waste m , uch lead by ski m ming ,

i t i s advi sable t o float a w ro ugh t i ron ri ng on the l ead j ust large eno ugh for -

t he ladl e to p ass thro ugh and to di p the lead fro mthe ri ng Th us o nly a
, .

very small surface wi ll have to be kep t bri gh t Wi th large tonnages hard .

,

lead i s molded as i s sof t lead Analyses of hard lead and hard lead dross .

are gi ven i n Table 1 44

2 63 Tin Skim
.

. mi ng Ti n ore occurs so rarely wi th lead si lver ores that i t i s

— -

only an excep ti onal case when ti n ski mm i ng i s form ed i n sof teni ng l ead b ul li on .

At Frei berg Saxony the ti n of the ores beco m

,
es co ncentrated to so m
,
e exten t i n

the lea d bulli on p roduced The ski m mi ng that ri ses to the surface i n the soften
.

i ng f urnace after the dross has been rem oved has th e followi ng com p osi t i o n :
I

PbO SnOg Sb205 A3 20]; 4 73 CuO p e r c ent ; an d co n .

, .

tai ns oz Ag p er t on Plat tner has i ntroduced a m

. ethod of desi lveri z i ng
.

thi s ski m mi ng and concentrati ng the tin i n a marketable alloy whi ch contai ns
Sn 33 Sb 1 4 As 1 p er cent ; the rest bei ng lead
, ,
Detai ls wi th analyses . .
,

of i ntermedi ary produc ts are gi ven i n th e reference ,

.

2 64 Kettle Dross
.
— The i m p uri ti es i n thi s dross are very few I t consi sts .

pri nci p ally of lead oxi des m i xed wi th m etalli c l ead and i s usually p ut b ack i n t o ,

the sof teni ng furnace wi th the next charge af ter the furnace dross has been drawn
off. Thi s i s the best w ay of di sposi ng of i t .

gave Iles, I
Si 02 cent Cu trace As none Sb
Fe Pb Zn p er .
, , ,

p er c ent A g 1 oz p er t
.on ,
and Au t r ac e T he p erc entag
.e of Sb i s ex cep ,
.

ti onally hi gh I t i s al so si ng ular that th ere sho ul d be present traces of Cu

.

and Au The ski m .mi ng i s best treated i n a reverberatory furnace that is used
for no o ther p urpose excep t perhaps for li q uati ng hard lead i n whi ch case
, ,

the lea d resul ti ng fromthe refini ng ski m mi ng i s sold as second class lead o n -

acco unt of the Cu i t has tak en up If th e reverberatory i s us ed only fo r .

reduci ng refini ng ski mmi ng the resul ti ng lead can be worked i n wi th th e ,

regular refini ng charges and corrodi ng lead produced The h ea rth of a , .

furnace sui ted for thi s p urp ose may be 1 0 by 5 ft and 9 i n deep b ui lt of .
, .
,

fire bri ck i nc losed i n a wro ugh t i ron p an

-
It will have an i ncli nati on of 3 in -
. .

fromthe bri dge to the flue where the mai n worki ng door i s placed ; a second ,

door i s placed i n the m i ddl e of one of the si des to i ntroduc e and di stri bute t he
charge The tap hole below the flue di scharges the lead i nto a small spheri cal
.
-

kettle havi ng a fireplace beneath The E ngli sh or Si lesi an .

reverberatory furnace al so serves the p urpose very well .

I
Plat tner, B erg H uttenrn Z . . .
,
1 883 , x m4 , 1 7
.

I
S chool Mi n Quart .
,
1 899 , xx , 39 7 .
DE S ILVE RI ZA TI ON OF LEAD B ULLI ON
586 ME TALLURGY OF LEAD

The mode of
operati on i s as foll ows : The hearth of the f urnace dark red ,

froma previ o us charge i s covered wi th a 2 i n layer of fine coal to pro tect i t ,

-
.

fromthe corrodi ng eflect of the ski mm i ng I t i s then fill ed w i th ski m mi ng .

mi xed wi th 1 0 p er cent of fine coal leavi ng roomfor the gases to p ass So me .

,
.

ti m es the ch arge r each es o nly to the worki ng door s b ei ng r enewed fro mti m e ,

to ti m e as i t shri nks As the charge heats lead wi ll flowi nto th e sum

. p wh ence , ,

i t i s tapped at i ntervals The fire i s gradually urged ; when no m . ore lead fl o ws

the charge i s rabb led and wh en exh austed i t i s drawn , , .

Fo ur tons of ski m mi ng yi eldi ng about 60 per cent lead are worked i n 1 2 ,

.
,

hr tw
.
,
o m en at tendi ng the furnace .

The resi d ue whi ch contai ns Pb Zn Sb perhap s som

,
e As and coal ash e s is , , , , ,

ad ded to th e sm el ti ng ch arge of li quated sof teni ng ski m -

mi ng .

A large furnace used i n connec ti on wi th the tw ,

o 300 ton so f teni ng f urnaces -

shown i n Fi gs 51 7 52 4 i s r ep resented i n Fi gs 63 1 634 The fi rep lace i s the

— — . .
.
,

sam e as th e one gi ven i n Fi gs 59 2 594

—
The furnace slopes fromfirebri dge to . .

has a chargi ng door i n the roof near the upp er end

°
flue at an angl e of 4 4 5
’

tw o wor ki ng doors at the si des a lead well w i th tap hole and a tap to em , p t y t h e - -

f urnace The hear th 1 6 ft 4% i n by 8 ft 4 % i n i s b ui lt i nto an i ron p an

.
,
. . . .
,

whi ch rests on cross rails supported by longi tudi nal I beams ; the lat ter are car
- -

ri ed by cross walls covered wi th i ron p lates The bottomhas two di vi si o ns

-
.

th e lo w er 9 i n t hi ck serves as a r ec ei ver for r ed uced l ead ; the upp er

,
.
, 1 8 in ,
.

thi ck i s th e worki ng floor for t he charge

,
The m ode of operati ng i s si mi lar .

to the one di sc ussed i n § 2 54 .

The refini ng ski m mi ng i s someti mes charged i nto the softeni ng f urnac e ,

after the dross has b een rem oved i n order to assi st i n the oxi dati on of As and Sb , .

The form er O bj ec ti on to thi s proc edure th at zi nc enter s th e hard l ead wh en ,

the ski m mi ng i s melted i n the blast f urnace has lost i ts i mportance si nce the ,

p r es e nt m etho d of s m e l t i n g i n a r ev e rb e r at ory f u rn a c e w i th g al e n a h a s co m e

i nto use .

A D Di vi ne has devi sed a process for recoveri ng as i m

.
I
.
p u re o x i d e t h e z i n c
of the refini ng ski mmi ng The process formerly i n operati o n at the Nati o nal .
,

W orks of So uth Chi cago consi sts i n cr ushi ng the ski mmi ng to M ln si ze ,
-
.

i th N3 2 C03 and pulveri z ed Oi l cok e ( 1 ton ski m

,

ng w mi ng 1 75 lb soda ash -

, .
,

4 0 0 lb cok
. e) a n d s m e l t i n
,
g t he m i x t ur e o n a le a d ba th i n a n o il fi r ed re v e r -

beratory furnace when Pb and Sb are taken up by the m . etal whi l e Zn and w i th , ,

i t so m e Pb i s vol atili zed o xi di zed and col lec ted i n a bag ho use
, ,
The charge , .

i s sti rred at regular i ntervals thro ugh one door only i n order to avoi d coo li ng .

Wh en the Zn has been b urnt off the oil burner i s stopped and the slag ( soda ,
-

ski m ) r em ov e d T he sl a g wh.i ch a m o un ts t o 1 0 to 1 5 p e r c e n t
, of th e w ei gh t .

of the ch arge goes to the hard lead blast furnace ; the zi nc oxi de i s t rea ted
,
-

el ec troly ti c al ly ; and the l ead f orm s a second class pro duc t In 2 4 hr th ere are -
. .

t reated 1 8 tons ch arge Fro m lb refini ng ski m . mi ng (Zn Pb .

Sb p er c en t ) w i t h 33 00 lb Zn. lb P b a n d 1 2 00 lb S b ( or .
,
.
, .
,

lb anti m
. oni al lead) there were prod uced lb anti moni al lead and 382 5 .

I
Tr A I
. . . M . E .
,
1 9 1 4 , x ux , 81 4 .
588 ME TALLURGY OF LEAD

2 68. Li tharge — reduced i n a reverberatory furnace or goes to the

Thi s is
bulli on blast furnace; i f free fromCu i t m ay be added to the sof teni ng furnace ,

af ter drossi ng Tho ugh the reduc ti on of li tharge i n the r everberatory f urnace
.

i s pr eferable froma m etallurgi cal and econo m i c poi nt of vi ew the blas t f urnace ,

i s in m ore com mon use as refini ng works are thus enabled to smelt dry si lver ,

ores at a smaller charge than W estern sm elter i es whi ch usuall y sufl er from ,

scarci ty of lead or es It is im por tant for a refinery to smel t some ore i n t r eati ng
.

by produc ts i n order to m
-
ak e newslag and not be forced to sm el t old slag ov er ,

and o ver whi ch i s expensi ve and causes losses i n l ead and si lver as these slags
, ,

become gradually v ery ri ch i n zinc

Old retorts, cupel bottom
.

2 69 . s, etc , are added t o the charges of t he .

b ulli o n blast f urnace .

2 70 Results and Cost

.
— The o utp ut of si lver w i th average lead b ulli on ,

r unni ng from1 50 to 300 oz Ag and j: 0 5 oz Au p er ton bei ng pret t y free .

, . .
,

fromdross but contai ni ng som , e As and Sb i s nev er less than p e r ce n t ; ,

.

generally there is a sli gh t surplus of Ag as the losses i n the com merci al assay ,

are not tak en i nto acco unt i n co nsideri ng the si lver that entered the p lant .

W i th Au the yi eld i s from98 to 1 00 p er cent ; a surplus i s rar e unl ess the lead
,
.

bulli on i s very ri ch i n gold Wi th Pb the r ecovery i s from98 to 98 5 p er cent .

, . .

as long as the b u l li on contains li ttle As and Sb; wi th b ulli on assayi ng As 2 and

Sb 3 p er cent the lead loss will r each 4 and 5 per cent
. .

N o detai led statem ent can be m ade abo ut the cost of r efini ng that w o ul d

be generally appli cable as the si ngle i tem s vary grea tly i n difl erent r efineri es
,
.

Il es
I
gi ves the Oper ati ng expenses at Denver Colo i n 1 900 as 5p er t on of , .
,

l ead bulli on excluding reworki ng of i ntermediary produc ts and overh ead

,

charges At present thi s cost i ncl udi ng the reworki ng of i ntermedi ary produc ts
.
, ,

ranges from 5 t o p er ton dep endi n g u po n th e s i ze of pl an t a n d t h e ,

faci li ti es for handl i ng m ater i als If overhea d charges such as i nterest salari es .
, , ,

mark eti ng etc are taken i nto account the above figures wi ll have to be
,
.
,

do ubled .

A good size plant i s one whi ch treats about 5000 to ns lead b ulli on p er m
-
ont h .

The works of the Inter nati onal Lead Refinery E ast Chi cago I nd wh i ch ha ve , , .
,

an annual capaci ty of tons lead bulli on are val ued i n th e repor t of th e ,

Anaconda Copper Mi ning Co at (p r e w ar pr i c es) whi ch eq u als .

-

p er to n of l ea d b u lli o n I
.

2 71 Records
.
I—
In a refinery where so m .any i nterm edi ary prod ucts r esul t ,

i t 18 essenti al to k now howm uch si lv er gold and lead i s contai ned In each of , ,

them These q uanti ti es vary a gr eat deal wi th the difi erent ki nds of b ull i on
.

trea ted I t i s th er efore essenti al to be able to fo llow up the m

. etals fromthe

A formof the so called kettl e

“
ti m e they ent er th e refinery unti l th ey lea v e i t .
-

”
book i s subjoi ned .

I
E ng . Mi n J . .
,
x x, 1 85
1 900, x .

I
I ngalls, E ng M i n J 1 9 1 7, c , 1 0 5 1 . . m .

I
Argall, M i n S c Press, 1 906 , xcrrr, 5 73, 7 2 2
. . .
 DE S I LVE RI ZA TION OF LE AD B ULLI ON 589

KE IT LE Boox I

M onth Day
INo .

Au, Ag A8 . Au As. All

I t i s to be no ted that the wei gh t in kettle before addi ng the fir st zi nc

net , ,

i s fo und by deducting the sumof wei gh ts of sof teni ng dross skim mi ngs and
, ,

k ettle dross fromthe lead bulli on charged i nto the sof tening f urnace The .

net wei gh t i n k et tle af ter addi ng the fir st zi nc i s fo und i n a si m

,
i lar w
, ay by ,

addi ng the po unds of zi nc used for m aki ng the fir st crust to the net wei gh t before

the fir st zinc addi ti on w as m ade and ded uc ti ng the wei gh t of the fir st crust fro m
,

this sum .

The o ther pri nci pal books kep t i n a refinery are: the r etor t book ; the

Ow
I i ng to th e f or m of this volu me
, i t has been necessary t o p ut the headi ng n four
s i
rows one beneath the other, -
m
but i n the actual kettle book they si p ly run across the tw o

O p p osi te pages i n one li ne .

590 ME TALL URGY OF LE AD

c upellati on book ; the books for reverberatory f urnaces I ( li q uati ng sof teni ng
-

dross and ski mmi ng ) II (reduci ng refini ng ski mmi ng and li q uating ha rd
-

,
-

lead) and II I ( smelti ng dro ss and ski mmi ng wi th galena) ; and speci al
,

assay books for the sof teni ng fur nace desil ver i z i ng k ettl e r etorts c upelli ng , , ,

f urnaces etc , .

2 72 Relati ve Advantages of Park es and Pattinson Processes

.
— The m any

advantages that th e Pa
I
rk es process has over that of Pat ti nson have made i t
the d esi lveri z i ng process used i n th e Uni ted S tates Th ere i s however one .
, ,

i nstanc e i n whi ch Patti nson m i gh t be preferr ed to Park es I t i s when th e .

lead b ulli on i s ri ch in B i Duri ng the crystalli zati on B i fo llows the li qui d .

,

lead I t i s thus concentrated i n th e ri ch lead and can be recovered wh en th i s

.
,

i s bei ng cup elled The B i co ntent of th e m ark et l ead th us b ecom

. es very m uch
lowered al though not q ui te removed In Park es p rocess the Bi enters onl y to
,
.
,

a sm all ex tent i nto th e zi nc cr ust w i th the r esul t th at the r efined lead m ay ,

beco m e r i ch er i n B i than the or i g i nal bulli on Thi s di ffer ence i s show n by th e .

tw o analyses in Table 1 3 5 by Kam p e

I
fro m L a u tent h al m ark et l ead wh er e ,

Park es process replaced that of Patti nson

’
.

TAB LE 1 45 — AN ALYS E S or PATTI N S O N A N D PAa

. s RE FIN E D LE AD LAUT E NTHA L ,

An i nteresti ng combi nati o n of the two processes i s fo und at Frei berg ,

Saxony where the or i g i nal lead bulli o n contai ni ng from 1 1 6 to 2 33 oz Ag

I
, , .

p er t on and fro , m to r ar ely p er c e n t B i i s co n c en t r a te d by .

,

crystalli z ati on to a li q ui d lead wi th p er c en t B i a s sa y i ng 8

5 3 o z A g .
, .

p er to n wh i ch i,s c up ell ed wh i l e t h e cry sta ls av e r ag i n g 3 0 o z A gp

,
e r to n a re .

desi lv er iz ed w i th zi nc the bi sm uth i n the m ark et lead not exc eedi ng

, p er

cent .

Larg e shi p m ents of lead bulli on w i th co nsi derable quanti ti es of bi sm uth

are of rar e occ urr enc e i n r efini ng work s Occasi onal ones are work ed i n wi th .

o ther b ulli o n that i s free fro m or at leas t low i n bismuth , , .

The prac ti ce of Frei berg has been reversed i n the Uni ted S tates where the
lead bulli on usually show s hi gher values than th at treated i n E urope The .

l ead bulli on i s desi lv er i zed by m eans of t he Park es process and the Bi content ,
-

of the refined lead lowered by Patti nsonizi ng to p er c e n t th e di v i di n g li ne .

,

between corrodi ng and non corrodi ng lead -

.

At the Internati onal Lead Refinery of E as t Chi cago refined Parkes ,

I
Phi li p s, E ng M i n J . . 1 88 7, X LI II , 6
3 3 .

I
Zt B erg H utten S al
. . . . W . i Pr ,
. . 1 8 70 , XVIII ,
1 95 .

I
E ng . Mi n J . 1 886 , x u r, 4 00 ; B erg II IlttennI Z
.
'

. .
, 1 88 7, x wr 4 5 , , 192 ; 1 889 , X LVI I I , 1 16

H ulst , Tr A I . . . M . E .
,
1 9 1 4 , x u x , 53 2 .
592 ME TALL URGY OF LEAD

2 Arseni c and Anti

. m ony —These t o . w metals are i n par t vola ti li zed ,
in
par t oxi dized and scorified by li tharge form i ng ski m mings j ust as in the soften ,

i ng of lead b ulli on They have no speci al i nfl uence on c upellati on prop er

. .

3 B i
. s muth — Bi sm u th i s con centrated wi th the Ag i n the Pb until t oward

the end of the process and then greatly retards the progre , s s of the work .

I t i s finally o xi di z ed and enters the li tharge gi vi ng thi s a greeni sh color and is , ,

absorb ed by the h earth m ateri al whil e the Ag also retai ns som e Bi w i t h great ,

tenaci ty —
The freezi ng poi nt curve of the all oy seri es Ag Bi Fi g 63 5 shows-
I
.
, .
,
°
an eutecti c wi th 97 5 p er cent Bi freezi ng at 2 6 2 . C and a soli d soluti on of .
, .
,

Bi i n Ag of 5 p er cent If the Bi i s to be recovered the Ag i s concentrated only

.
,

to a certai n degree ( say to 50 or 60 p er cent ) i n the Pb whi ch i s then cupell ed .

,

i n a separate furnace; the sat urated part of the hearth of thi s f urnace and t he
li tharge formthe rawm ateri al for the extrac ti on of bi sm uth i n the w et w ay .

Tell uri um Thi s has a strong afi ni ty for Ag si m

I
.
~ -
i lar to that of Cu T he , .

research of Pelli ni and Q uerei gh has show n the existence of t w o chem i cal com
I

pounds the stable AggTe ( hessi te) mel ti ng at 959 C and the unstable AgTe
, ,
°
.
, ,

mel ti ng at whi ch undergoes a change at 4 1 and tw —

o eutec ti cs Ag AggT e ,

wi th about 1 2 p er cent Te freezi ng at 872 C and Ag, Te(AgTe) Te wi th .

— °
.
,

abo ut 70 p er cent Te freezi ng at 3 . The later work of Chi kasi gi and Sai to
,
‘

replaces AgTe by Ag7Te4 Cop per form II

s wi t h Te the tw o co m po unds Cu.T e;
.

( 6 2 0 C
°
) an
.d C u gTe ( 8 56 I n c u pelli n g r et or t b ulli o n w i th°
p er c ent T e .

at Pert ulosa I taly the produc ts gi ven i n Tabl e 1 46 were Ob tai ned
, , .

TAB LE 1 46 — PRODoc rs n on CU PE LLI NG -

LEAD BULLIO N CO NTAI NI N G TE LLURIU II

Products

Fi rst li tharge
Crude si lver, while brigh ten Trace Trace ( G)
i ng .

Second li tharge Trace Trace

Refined silver Trace Trace Trace 0 . 6 34 0

Products

Crude silver, while bri gh ten

i ng .

Second
Refined si lver Trace Trace

( a) B y di fi ere nce .

I
Petrenko, Zt . anorg . Che m .
, 1 906, L, 1 38 .

I
H eberlei n, B erg H i tttenrn Z . . .
, 1 89 5, LI V, 41 ; Mi n . I nd , . 1 89 5, I v, 4 81 .

I
Atti Reale Accaderni a def Li ncei , 1 9 1 0, 4 1 5, 44 5, th ro ugh J . I nst M et
. 1 91 1 , v 3 1 7
mAb t a t
.
, , .

I
M ens Coll S c Kyoto I peri al Uni v , 1 9 1 6, I , 3 1 6 ; through Che
. . . m . . s r c s, 1 9 1 7, xx, 4 4 7 .

I Chikashi ge, Zt anorg che , 1 907, LIV, 54. . m .

 DES ILVE RI ZA TI ON OF LEAD B ULLI ON 593

m
A sa ple of the si lver shown i n the duri ng bri ghteni ng had a table, taken ,

blui sh gray color was bri ttl e and showed a fine grai ned frac ture In order to
-

, ,
.

rem ove the i m puri ti es some lead was added gi vi ng the second li t harge and , ,

refined si lver Of t he Te contai ned i n the crude si lver 6 1 p er cent entered

.
,
.

t h e li t h arge p e r c e n t r e,
m a i n ed i n t h e r e fi n ed s i lv e r an d
. t h e d i ff e r en c e , ,

p e r ce n t w a s vol a ti li z e d or. a, b s orb ed by t h e h ea r t h m a t er i a l T h e vo la t i le .

character of Te was clearly shown by assays of flue dust samples from70 to ,

9 0 f t fro .m t h e f u rn a c e b e i n g ri ch e r i n T e t h a n t ho se clo se by .

5 S .at e en — T h e li th a rg e ob t a i n e d i n c up e l li n g a lw a y s co n ta i n s so m e A g ,

t h e am o unt i ncreasi ng wi th the ri chness of the lead The presence of Ag i s .

d ue to parti cles Of argentifero us l ead carri ed m echani cally by t he li tharge ,

a nd to Ag or so m e Ag o held i n sol uti on by the li tha rge Stahl finds that Aggo
I
g .

l o ses O at 1 30 C and canno t therefore exi st at a c upelli ng tem

°
. perat ure of abo ut
On the o ther hand Wai t di ssolved fro mli tharge contai ni ng
.

° I
8 00 C .
,

p e r c en t A g by m. e a n s of cold , a c e ti c a c i d p e r c e n t of th e A g
— co n te n t ,
.
,

a nd when bro ugh t to a boi l as m

,
uch as and p e r c en t
, of t h e A g; .

when added boi li ng no Ag went i nto soluti on As Ag i s i nsol uble i n the aci d , .
,

t he si lver m ust have been pr esent as an oxi de unl ess th ere i s form ed a si lver

p l um b i t e a bo u t wh i ch n o t h i n g i s k n ow n K ohl m e y e r ’
who i n v es ti g a t e d t h e .
,

s ubj ec t cam e to no concl usi o n as to the formi n w

,
hi ch Ag i s present ; he
fo und however that m ,
olten li tharge co uld di ssolve fro m3 to 6 p er cent Ag
, .
,

a nd that i ts freezi ng po i nt w
°
as lower ed by t he Ag to 84 0 C -
Dudl ey finds ‘
.

t hat the di ssolvi ng p ow er of li tharge at 1 1 00 C for Ag i s 7 ti m

°
es as gr eat .

a s that at i ts m elti ng poi nt H i s experi m ents show that li th arge i n co ntac t

-
.

wi t h lead b ulli on wi ll di ssolve Ag unti l the di stri b uti on equi li bri umfor a gi ven
t em perature has been establi shed If the li tharge was ri cher i n Ag than the .

b ulli on Ag wi ll be tak en up by the b ul li on unti l t he eq ui li bri um has been

,

reached H e finds that the concentrati on of Ag i n li tharge i s di rec tly pro

.

p or t i o n a l to i ts co n c en t r a t i o n i n t h e b ul li o n ; t h at for b u lli o n w i t h u p t o 8 or
1 0 p er cent Ag the concent rati o n of the Ag i n the li tharge i s propor ti onal to
.
,

t he wei gh t p ercentag e i n t he b ull i o n; and t hat w

-
i th ri cher b ulli on the pro
p o rti o n a li t y li es b e t w ee n t h e at o m i c or m o le c u la r p e rc e n t ag es of A g i n li t h a rg e

a nd b ulli on As regards the formi n whi ch Ag i s pres ent i n m

. ol ten li tharge ,

h e hol ds that bei ng a goo d conductor of elec t ri ci ty m ,

ol ten li t harge o ugh t to ,

s ho wso m e degree of di ssoci ati o n and th at the Ag present i n sm all q uant i ti es , , ,

o ught to be m ore or less di ssoci a ted and be present for the most part as Ag i ons .

6 Gold .
— Thi s follo w . s the Ag i n th e c upellati on but none of i t or perhap s , ,

a trace i s fo und i n the li tharge

, .

Accor di ng to th e general construc ti o n of the f urnace and the co nseq uent ,

mode of operati ng cupellati on i s generally di scussed under two heads : German ,

C upella ti on and E ngli sh Cup ellati on .

I
M etallurgi e 1 90 7 Iv 688 -
, , , .

I
Tr A I M E 1 886 8 7
.
— . . . . xv, 4 63 .
, ,

I
Che mZ 1 91 2, X XXVI 1 0 79

M et ChemEng
. . .
, ,

I
. . .
, 1 9 1 6, xrv, 636, 69 5 .

88
594 ME TALLURGY OF L EAD

2 74 . Ger man characteri sti cs of thi s meth o d

Cupellati on, General .
I — The
are: that a large r everb eratory f ur nace wi th a fixed bed and a m o vable roo f ;
that the b ul li on to be c up elled i s all charged at once; and that the si lver i s
not refined i n the sam e f urnace i n w hi ch the c upellati on was carri ed on .

2 7 5 Furnace .
— The f urnace select ed for il l ustrati on i s the one i n operati o n
at Pfi bram ( Fi gs 636 I t di fl ers so m ewhat fro mthe generally acc ept ed
I
.

ci rc ular form and i s an i mprovement on i t Fi g 636 shows the fireplace a a t

3
,
. .
, ,

the ri gh t and th e fl ue b at the l ef t of the hear th

,
Fi g 63 7 represent s a h o ri
, , ,
. .

’
zontal sec ti on of one f urnace and the fir eplac e a of a second furnac e th e , , , ,

f urnaces bei ng b ui lt i n pai rs The products of combusti on p ass downwa rd .

t hro ugh fo ur separate flues b w hi ch uni te i n one mai n flue c leadi ng to the d us t , , , ,

chambers In Fi gs 638 and 639 are seen two verti cal secti ons on the same li ne
. .
,

EF Fi g 638 representi ng the f urnac e before Fi g 639 after tam

,
. ping i n th e ,
.
,

hear th The furnace i s b ui lt of common red bri ck wi th th e excepti on of th e

.
,

p ar t s th at a re expo sed to t he fl am e as i ndi cat ed by th e cro ss h at ch i ng I n t h e ,

-
.

upper part of the fo undati o n and i n the si de w al l s sm all ch annel s d and e rea ch , , , ,

i ng o utward are lef t open Th ey serve as drai ns for the m

,
oi sture At the back . .

of the furnace are three openi ngs f through whi ch the tuyere pi pes are i nt ro , ,
-

duced At the front i s the li tharge channel g whi ch can be closed by a sli di ng
.
, ,

door ; a cast i ron breastp late h serves as supp or t for the upp er hea rth i
-
T he , , , .

movable arched roof k rests on an angle shaped cast i ron ri ng I and i s remo ved , ,
- -

, ,

wi th a di fferenti al p ulley susp ended froma traveler On the foundati on i s .

bui lt a bri ck bo ttom m the bri ck bei ng set dry Beneath i ts lowest p o i nt j ust , ,
.
,

belowthe cavi ty n i s a cast i ro n p late a to prevent any leakage of metal thro ugh
, ,
-

, ,

the drai n d sho ul d the work i ng h earth crack or be i nj ured i n any o t her w
, ,
ay .

The flues leadi ng fro mthe fireplac e a to the hearth are sho w n in j The fi re , , .

b ri ck p art of the furnace i s encased i n cast i ron p lates that have openi ngs cor -

respo ndi ng to the up per drai ns The whole furnace i s well bo und toget her by .

buckstays and ti e rods The f uel used i s a m i x t ure of bi tum

-
i no us c oal a nd
.

li gni te; the ash p i t i s closed as undergrate blast i s used

-

, .

2 76 Plattner Cupelli ng Furnace

.
—
In t hi s connecti on m ay be m enti o ned

the Plattner m I
odi fied German c upelling f urnace It has the formof a rever
‘
.

beratory furnace ; the hearth i s rec tangular i n plan ( 1 3 by 834 and recei v es

i ts blast fromtw o pi pes on ei th er si de of the firebri dge; the li tharge c hann el

I The author i s fully aware th at the Germa n cup elli ng furnace i s hardly found i n thi s coun

t ry, and has been gi ven up i n any E urop ean co nti nental p lants If, nevertheles s, the sub m .

jcet i s treated here i n ore detail than ay see m

necessary, the reason i s that t he step s co m m m
mn t
o both typ es of furnaces
o can be made clearer wi t h the German furnace ,
as here the enti re
bulli on to be cupelled i s charged at the start and not gradually as wi th the E nglish furnace .

T hus, the several stages of followone another i n thei r regular order the p rocess , and do no t
o verlap and beco me obscured as i s the case wi th the E ngli sh meth od o f worki ng .

I
Oesterr J ahrb , . . 1 890 , XXX VIII , 4 6 ; Pri va tes notes, 890 1 .

I
Z t B erg H utten S al
. .
'

. . W i . . Pr , . 1 8 74 , xx n , 89 ; B erg H utten . mZ . .
,
1 8 72 , xx xr, 415 .

4
D rawi ngs i n Arche D i e Gewi nnung der Metalle Lei p si c , ,
”
,
1 888, H ef t 1, Plate 1 .

Schnabel Loui s H andboo k of M eta llurgy 1 90 5 I 705

”
-
.
, , , ,

Results i n B erg H Ii ttenmZ . . .

, 1 886, X LV, 2 1 1 .
596 ME TALLURGY OF LE AD

is at the op posi te end beneath the flue whi ch carri es off the prod uc ts of co m , ,

busti on as well as the lead fum es Less f uel i s requi red and less m etal vola tili zed .
,

because the li tharge need not be heated to such a degree to remai n li q ui d ; a nd

no f um es enter the c upelli ng roo m as th ey are all carri ed O ff wi th the f uel gases ,
.

Most of the E ngli sh c upelli ng furnaces erected at present are co nstruc t ed on

the Plattner m odel .

2 77 Mode of Operati ng
.
— The operati ons necessary to w ork a charge a re
si x i n num ber : prepari ng the worki ng bo ttom chargi ng and firi ng the f urnace , ,

sof teni ng the b ulli on c upelli ng the sof tened b ul li on rem ,

ovi ng the cr ude sil ver , ,

and refini ng the crude si lver .

1 Prepari ng the Worki ng B ottom The m — ateri al to be sui ted for prep ari ng

the hear th m ust be basi c m ust not be attacked by the li tharge nor c rack m
, ,
us t , ,

be sufli ci ently p oro us to absorb so m e li th arge and free fro many red uc i ng agent ,

( org an i c m a tt er m e t a lli c su lph i d e ) ,

T he m a te r i al m o st u s e d i s a m a rl T h e . .

co mposi ti on of that used i n the H arz Mo untai ns vari es accordi ng to Kerl and ,

Wi mmer wi thi n the followi ng li mi ts : Si O,

I
,
to A130; to
FegO a 3 54 to 5 39 CaCO ;
. to .
,
MgCO; to p e r c en t U su a lly .

the h ear th m ateri al i s a m i xture of dolo m i te or li m esto ne wi th fire clay Fo r -

.

i nstance at Tarnow ,
i tz a dolo m
I
i te of the co m po si ti on Si 02 A120; ,

FCgO g CaCO ; MgCO ; is m i xed wi th 2 5 p er c ent o f .

clay At Frei berg 2 vol blue marl ( CaCO;

.
I
MgCO ; Fe( Al ) 303
.
,

clay substance 38 p er cent ) and 1 yellow marl ( CaCO ;

-
MgCO s .

Si os A130; FeCO ; H 30 p e r c en t ) ar e cr u s h e d i n a b a ll .

mi ll wi th 1 0 p er cent clay (A130; Slog Mgo . CaO

Fe, o, KgO p er cen t ) t o su i t a bl e s i ze A t P i i b ra m thr ee p a r ts . .
'

of li mestone are gro und together wi th one part of clay so as to pass a 5 mesh -

si eve ; at o th er places an 8 m esh si eve i s used The hearth m ateri al has to -

.

be m oi stened before i t i s beaten down i n the f urnace For thi s p urpose i t i s .

,

sp read on the floor sp ri nkl ed w i th water froma ho se and turned over and
, ,

over wi th a shovel that the moi sture may be eq uall y di ssem ,

i nated thro ugh the
powder If lef t over ni gh t i t must be covered wi th wet cloths and work ed
.
,

agai n the next day The m ateri al i s of the ri gh t consi stency if when pre
. s sed ,

i n the hand i t coheres to a l um ,

p but has not sufli ci ent moi sture to adhere to ,

the h and The hear th m . ateri al i s si f ted thr o ugh a coarse hand si eve j us t -

before usi ng and any lumps that may have formed are broken up or t hro wn
,

asi de So m
. eti m es i t i s i ntro duc ed all at once so m eti m es i n t w o separate lay ers ,
.

The latter i s the w ay at Pi i bram as Fi g 639 shows i bei ng th e up per and i

‘ '
.
, , , , ,

the lo w er bo tto m Before the prepared m . i x t ure i s p ut i n the bri ck bo tt o mi s ,

spri nkled w i th water that i t m ay no t tak e up any m ,

oi sture fro mthe hear t h
materi al At Pfi bramthe lower bottom i i s first tamped down to the form
.
'

,
’

shown i n the dr aw i ng The tool req ui red the tam pi ng i ron i s a cast i ro n
.
,
-

,
-

di sk of abo ut 6 i n i n di am eter and 1 i n i n thi ck ness wi th a sock et i nto w

.
hi ch .
,

I
Berg H i l tten . mZ . .
, 1 853 , X II , 2 4 1 .

I
Zt B erg H i aten S at
. . . . W i . . Pr , . 1 884 , xxxrr, 1 07
I
Kochi nke, Frei berg J ahrb , . . 1 89 8, 9 8 .
 DE S ILVE RI ZATI ON OF LEAD B ULLI ON 597

fi ts wooden handl e abo ut 4 ft long The tam

a pi ng i s begun at the center . .
,

p roc eed s i n t h e for m of a s pi ral to t h e si d e w a lls an d r et urn s i n th e sa m e m an ,

ner care bei ng taken that the c i rc ul ar i ndentati ons shall overlap i n par t those
,

made i n working outward By gi vi ng attenti on to this poi nt the surface wi ll .

,

be beaten evenly whi ch i s essential ,

Before putti ng dow n the upper bo t to m .
,

t he surface of the lower one i s ro ughened by scrat chi ng wi th the poi nt of a

chi sel Thi s i s done that the bo tto mto be p ut down may adhere to the one
m
.

al ready i n pl ace The tam ng of the upper bo tto mi s done i n the sam
. e w ay

as the lower o nl y the surfac e when fini sh ed m

, ust be perfec tly sm ,
ooth It i s , .

of pri me i mp ortance that the hearth sho ul d have j ust the ri ght degree of hard
ness Thi s i s easi ly i ndi cated to the ear and hand af ter a li t tle experi ence
. If .

t oo hard i t w i ll crack and not be sufi ci ently p oro us ; i f not hard eno ugh i t wi ll
, ,

absorb too m uch lead .

If the m ateri al w as too dry the h ear th wil l peel when
.
,

heated ; i f too wet i t canno t be beaten to the desi red hardness as i t acts li ke
, ,

a c ushi on In order to prevent i ts adheri ng to the tam

. pi ng i rons these are -

sli gh tly w arm ed The thi ckness of the hearth at the bo tto mand si des vari es
’

so m ewhat ; the l east i s perhaps 6 i n at the bo tto mand 8 i n at the si des . The . .

general rule for the c urvature of the hearth i s that the more co ncave the bed
i s the easi er w i ll be th e c upelli ng and th e harder the fini shi ng ; the flatter th e bed ,

t he harder the c upellati o n and the easi er the fini shi ng When the hearth i s .

completed a cavi ty n ( 1 i n deep and 34 i n i n di ameter) i s cut i n the deepest

, ,
. .
,

part to recei ve the si lver It i s si tuated a li ttle to one si de of the m . edi al li ne ,

t ow ard the fire b ri dge that the si l ver m -

ay easi ly be k ept m
,
ol ten at the end of
th e operati on .

2 —
Chargi ng and Fi ri ng the Furnace The furnace recei ves i ts charge of 2 5
t o ns of l ead enri ched by the Luc e and Rozan process
,
So m eti m es the bo t tom .

i s covered w i th straw b efore chargi ng to prevent i ts bei ng dam aged d uri ng the ,

operati on The bars are placed i n such a w

. ay as to leave an open space reachi ng

fro mthe t uyeres to the li tharge channel The hood i s then lower ed on a clay .

l ute placed on top of the f urnace The li t harge channel i s closed by loweri ng .

t h e door the fire ki ndl ed on the grate and soon the blast b elow let on
, , .

3 S of te
.n i n g th e B u ll i on — T h e l ea d m el ts d ow n s lowly . T h e dro ss ri ses t o .

th e surface and i s drawn off thro ugh the li tharge channel The tem perat ure i s .

rai sed and the blast p ut on thro ugh three tuyeres the ski mm i ng for m s and i s ,

drawn ofl and finally p ure li tharge takes i ts pl ace

,
At the very b egi nni ng .
,

when the dross i s bei ng removed b ubbles of gas are seen to pass ofl fromthe ,

surfac e of th e l ea d and th i s conti nues t hro ugh al m ,

ost the whole c upellati on .

They are m ai nly H gO vap or and are m i xed wi th CO, resul ti ng from the
-

deco m posi ti on of the m agnesi um and calci um carbonates of the h earth

materi al .

4 C u p .d li n g th e S o f t en ed B u lli o n — Th e t em p e ra t u re i s low e r ed a n d th e

vol ume of blast di m i ni shed Bo th are kep t low duri ng the larger part of the.

operati o n ; they are rai sed onl y toward the end wh en the enri ched si lver lead ,
-

all oy r eq ui res a hi gher tem perature to gi ve up the last par ts of lead When the .

ski m mi ngs have been removed and the cupellati on has somewhat progressed the ,
598 ME TALLURGY OF LE AD

convex surface of the lead wi ll be exposed to the ac ti on of the blast whi le the ,

lead near the peri p hery wi ll be covered wi th li tharge The wi dth of thi s ri m .

depends on the rate at w hi ch the li tharge i s allowed to run Off thro ugh th e li t h
As li tharge m a t em
°
arge ch annel
°
. elts at 883 C perature of 900 C has to be .
,
.

mai ntai ned i f i t i s to remai n li qui d Lead melti ng at 3 2 7 C would be vola ti l

, .
,
°
.

i zed to a consi derable extent i f fully exposed to the ac ti on of the bl ast at t hi s

,

hi gh temperature The li tharge i s therefo re allo wed to run 03 only to such

.

an extent as to gi ve the ri ma wi dt h varyi ng fro m1 2 t o 1 5 i n at th e b egi nni ng .

,

and of 5 i n toward the end of the op erati on

. The blast playi ng on the surfa ce .

of the lead forms small waves and dri ves the li tharge to ward the channel T he
,
.

pressure i s abo ut 8 oz p er sq i n and abo ut 300 cu ft of ai r are deli vered p er

. . .
,
. .

mi n thro ugh the three tuyeres In order to remove the li tharge a gutter i s
. .
,

cut i nto th e channel by m eans of a scraper Thi s i s an i ron rod 8 ft long and .
,
.

i n i n di am
. eter fl at tened out at bo th ends
, One of these i s bent to enci rcle .

a wooden handl e and t he o th er o nly sli gh tly flattened i s sh arp ened and bent
, , ,

to the for mof a hook In c utt i ng the g ut ter the enti re edge of the t ool m
. ust ,

be used and no t one of the corners

,
If larger p i eces of the breast are t o be cut .

out ,
i t i s do ne w i th a chi sel p oi nted bar say i n i n di am eter
-
Th e rat e ,
. .

at w hi ch the li tharge runs off depends on the dep th of the gutter and the strength
of the blast The dep th i s correc t wh en the li tharge runs 05 i n a t hi n st rea m
.

whi ch stops as soon as the blast i s lowered If i t runs too fast the ri mof .
,

li t harge i n the furnac e decreases and l ead i s volati li zed ; the li tharge i s ,

not sufli ci ently desi lveri zed fro mtoo short a contac t wi th the l ead beneath i t
,
.

If i t runs too slow ly the ri mof li tharge beco m ,

es too broad and the c upella ti o n

i s retarded ; there i s agai n lo ss i n si lver by the hi gher tem p erat ur e t h at i s re

q ui red to keep the larger amount of li tharge fl ui d and if the temperat ure be ,

not rai sed suffici ently l ead w ill be c arri ed out m echani call y by the li t ha rge
,
.

The li tharge g ut ter i s first cut i nto the breast on the si de far t hest aw ay fro mthe

fire bri dge and gradually m

-
oved toward the op posi te si de that the final li tharge ,

maybe drawn off as near the fire bri dge as p ossi ble The c urrent of t he li tharge -
.
,

wh en flo wi ng out of the furnace i s di rec ted i n such a way as to forma large ,

cake i n front of the furnace In so me i nstanc es a U shap ed p i ece of sheet i ron

.
- -

i s placed up ri ght i n fro nt of the channel that the li tharge m ay coll ec t i n a rec ,

tangular block Befo re rem ovi ng thi s the li tharge i n the center t hat i s sti ll
.
, ,

li q ui d i s tap ped fro mnear the bo t to mof the cake

,
The li tharge resulti ng from .

the c upellati on i s graded accordi ng to the si lver contents and the p ercentage
of i mp uri ti es (cop p er bi smuth i nto m ark etable li tharge and i nto a by
, ,

product to be treated by a sep arate process As the c up ellati on p rogresses to .

ward the end the temp erature i s rai sed and the blast i ncreased the si de tuyere
, ,

openi ng s are c losed and t w o t uye re pi p es i ntroduced thro ugh the central open
,
-

i ng; finally t he last fil mof li tharge di sap pears fro mthe surfac e of the lead wi th
,

a charac teri sti c p h eno m eno n th e so called bri gh teni ng wh i ch every rea der has
‘ -

, ,

watched whi le maki ng a si lver assay .

I
Van Ri emsd k , B erg H uttcnmZ . . .
, 1 880 , xxx rx , 2 4 7, 2 75, and Bock, o p . ci t 1 880, xxxrx ,
mad
.
,

409, have e i nteresti ng i nvesti gati ons on thi s sub j ect .

600 ME TALLURGY OF LEAD

q ui red to cupel
The ti mr e e the 25 tons of ri ch lead i s 80 hr . I t is di vi ded
as shown i n Table 1 4 9 .

TABLE 1 49 — T111 1:
. or CUPE LLI N G CH ARGE , PRIBR AII
H ours
Prepari ng the hearth mat eri al, making th e h earth , and chargi ng the lead . 8
Mel ti ng , and wheeli ng the necessary coal . 16

D rossi ng 6
D rawi ng the ti n ski mmi ng 6
ony ski m
.

Drawi ng the anti m mi ng 3

Runni ng 06 mk ar et li tharge 23

Runni ng ofi ri ch li tharge 1 8
80

The cupellati o n i s i n charge of three men each wi th a helper worki ng i n , ,

8 hr sh i f ts
-
. For every 1 00 tons of lead b ulli o n are consum
. ed tons of c oal
and 2 3 b ushels of h ear th m a teri al ( wh i ch i ncl ud es the r efini ng of th e si lv er ) .

The lo ss i n Ag i s p e r cen t ; t ha t i n P b p e r c en t T h e fi g u r e s .
,
.

do not i nclude th e lo ss endured i n re treating som e of the by prod uc ts - -

.

Th i r ty si x p er c ent of the l i th arge i s low eno ugh i n si lver to be sold i n th e

-
.

market the b ulli on fromwhi ch i t i s made averagi ng 1 67 oz Ag p er ton

, . .

5 R em
. ovi ng the C ru d e Sil ver — A f te r t h e s i lv er h as br i gh te ne d th e b la s t .
,

i s sh ut 03 th e tuyere pi pes are r em

, oved and the li tharge gut ter i s closed wi th
-

a ball of clay Tw o k ni f e sh aped pi ec es of wro ugh t i ron are i ntrod uced thro ugh
.
-

th e li th arge ch annel and pr essed into the cak e of cr ude si lver Fi rst w arm .
,

t hen col d water i s all owed to run i nto the furnace and the si lver then r em
, oved ,

thro ugh the c entral openi ng at the back I t i s cleaned wei ghed etc The .
, , .

f urnace i s lef t to cool ti ll the next day when the hear th i s examined for sm al l ,

par ti cles of si lver that have adh er ed to i t The upper hear th i s then removed .

wi th a pi ck Par t of i t i s soak ed wi th li tharge to a dep th of 2 or 3 i n This i s

. .

separated fromth e unso ak ed p art w h i ch i s m i xed i n wi th the hear th m ater i a l ,

-

for the next charge wh i le the lead soaked par t goes to the blast fur nace
,
-
.

6 Refini ng the Crude Sil ver

.
— The refini ng of the cr ude si lver has for i ts oh .

j ect t h e r em ov i ng of i m p u r i ti es wh i ch v ary fro m 2 to 1 0 p e r c e nt F or m e,r l y .

thi s w as done exclusi vely i n a sm all oval r everb eratory f ur nace h avi ng a work i n g ,

door at one si de or at the flue end and a worki ng bo ttomof similar com -
posi ti on ,

to the c up elli ng bo ttom the r easonbei ng th at the lo ss i n si lver and th e con ,

sum p ti o n of fuel were consi dered v ery much smaller than if the firi ng was done
i n the bi g c up elli ng f urnac e Ohl and Foehr have s i nce prov ed thi s not to cor
l I
.

respond to the fac ts and the r efini ng i n a separate furnace has r ecei ved a ch eck
,
.

Si nce Roessler d i scover ed how to refine crude si lver i n a plum

I
bago cr uci ble
by means of silver sulphate the refini ng i n a separate furnace has been ,

aboli sh ed enti r ely at som e works .

I
B erg Il fittenrn Z
. . .
,
1 8 79 , XXXVI I ,
2 74 .

I bid .
,
1 885, XLIV , 3 8 1 .

I
I bid .
,
1 889 , v m38 7 ,
.
 DESILVE RI ZA TI ON OF LEAD B ULLI ON 601

Refini ng in a cr uci ble i s mall works by ml ti ng th i lv r and carri ed on at s e es e ,

uncover i ng th cruci bl th at the ai r may o i di th i m

e puri ti e Th e ar e x ze e s . se e

sti fi n d by pri nkling bon a h or h a th m

e e at ri al on th
s i lver and th n e -
s e r e e s e re

moving i t wi th a ki mmr th op rati on b i ng r p at d ti ll n mor i mpuri ti

s e , e e e e e e o e es

ri se to the surface A slag ob tai ned by Curtis at W yando tte Mi ch sand bei ng
.
I
,
.
,

used i n r efi ni ng contained i n addi ti on to si li cate of lead the followi ng m

,
etals : ,

( N i Co) O C u o 3 130 3 Ag s O 4 A sa o g
— to tal er c ent
p .

Roessler found that if Ag3S04 i s added to m el ted Ag i n a cr uci ble fir st th e ,

Pb and then the B i are conver ted to sulphate s th e Ag bei ng at the sam e ti m e ,

set fr ee Cu i s not r em
. oved by AggSO4 By keepi ng separate the difi erent .

slag s he co ncentr at es th e B i i n a com parati vely small amo unt of slag to be ,

tr eated separ ately while the first slag contai ns m ost of the Pb To prevent
,
.

the cr uci ble frombei ng attack ed he i ntroduc es a layer of q uar tz sand on top ,
-

of the Ag and then stirs i n the Ag,SO . i n the m

,
i ddle The sand serves at th e .

sam e ti m e to sti ffen the slag whi ch i s th en r em oved wi th a ski m mer The ,
.

process as seen by the wri ter at the Lautenthal Smelting and Refini ng Works
,

i n 1 890 di fl ers sli gh tly fromthe m

,
anner i ndi cated above I t i s as fo llows : The .

Ag, SO 4 i s produced by di ssolvi ng Ag i n H , SO4 of 66 Bé i n a sm all cast i ro n

°
-

,
.
,
°
k et tl e The soluti on i s allowed to cool i s then di l uted to 60 Bé whereupo n
.
,
.
,

nearly all the AggSO , wi ll fall out as a sli gh tly y ellow cheesy m ass The super .

na tant li q uor i s draw n ofi as m uch as po ssi ble and the r em ai ni ng di l ute ac i d ,

dri ven off by heati ng Speci al arrangements are requi red to cool the vapors .
,

as th ey carry finely di vi ded AggSO . along w i th th em The tem p erature i s .

rai sed to redness i n order to f use the An 04 (mel ting poi nt 651 whi ch -

,
°
,

when li q ui d i s cast i nto molds and i s ready for use The color of the melted
,
.

sulpha te i s grayi sh gr een; i t i s hygrOSCOp i c and i s therefore k ep t i n a l ead li ned -

wooden box ; 1 000 par ts contai n 650 parts Ag .

Crude si lver of a fineness varying from950 to 980 tho usandths is m el t ed

i n a plum bago cruci ble holdi ng 700 lb The cruci ble i s heated wi th coke in .

a sm all cyli ndri cal furnace havi ng i n the lower par t tw o I M i n op eni ngs for -
.

the blast p i p es On tryi ng to sti r i n the AggSO4 as advi sed by Roessler

-
.
, ,

it w as fo und th at som eti m s i t got b eneath the lay er of sand spr ead ov er th e
e ,

si l ver and corroded th e cr uc i ble

, To prevent th i s a wrough t i ro n ri ng M i n .
,
-
.

thi ck 1 0% i n i n diam
, eter and 7 in h i gh) i s coated on ei th er si de wi th a 3 i n
.
,
.
-
.

layer of clay and placed on the si lver ,

Into the center are i ntrod uced wi th a .

ladl e fro m6 to 8 lb of sulphate ( the si ze of a hen s egg) that has been warm ed
’
. .

As soon as i t com es i n contac t w i th the sil ver thi s begi ns to boi l When the .

efi ect decr ease s the sil ver i s sti rr ed wi th an i ron rod to assi st the acti on of the
,

sulphate From 2 5 to 30 m
. i n af ter the sulphate has been added thi s i s .
,

completely deco m posed a slag has collected on the surface of the si lver and , ,

quar tz i s added to sti flen i t that i t may be r emoved w i th a sk i m mer ,

.

A second a th i r d and if necessary a fo ur th addi ti on of Ag, SO , i s gi ven to

, , , ,

make the si lver fine The test made for fineness is to di ssolve some Ag i n .

I
Tr A I . . . M . E .
,
1 8 73 74 , — 11 , 9 8 .
602 ME TALLURG Y OF LE AD

H N O; and to p r
su e sat u ate r wi th N H IO . N o preci pi tate mu t form
s e ven af ter
standi n g .

The a bo ut 1 55 ti mes the total

mount of Ag SO req ui r d t fine th Ag i , , e o e s a

q uanti ty e of bas mtal pre ent Thus 700 lb of

e s crude Ag bei ng 9 70 fine . .
, ,

co ntai n 2 1 lb of base mtal whi ch wo uld r q ui r 3

e . e e 1 lb of An o4 to be added ,
.

i n thr ee por ti ons If the test wi th N H 50 sho uld prov e th i s not to be sufi ci ent
.
,

an ex tra addi ti on i s m ade In 1 890 lb of cr ude Ag wi th an av erage .

,
.

fineness of 9 70 r eq ui r ed 6009 lb of An o4 whi ch corr esponds to a bo ut 2 parts .

of AggSO . to 1 par t of base metal N ot all the Ag of Ag, SO. is ta k en up by .

th e Ag in the cruci ble; par t of i t ent ers the slag as sho w n by the foll ow i ng ,

analysi s m ad e by H am pe : I

Si 03 P305 80, S FeO A130; Bi ,o;

PhO Ag, 0 Cu Sb CaO M gO
KgO N azO p er c en t .

The m ain adv antage of Roessler s

’
ethod of r efini ng i s t o be fo und i n the m
larger direc t o utp ut of si lver , and the concentrati on of the bis uth in a co pa m m
rati vely small am o unt of slag th at i s ore easi ly worked than c up el bot to and m -
m
li tharge ob tai ned i n the r everberatory used for refini ng the si lver .

2 78 Engli sh Cupellati on, G eneraL The ch arac ter i sti c s of thi s m

.
— ethod are ,

a sm all or large reverberatory f urnac e wi th a m ovable bed and a fix ed roof ,

and the fac t that the b ull i o n to be c upell ed i s charg ed grad ually and the silver ,

usually r efined i n the sam e f ur nace i n wh i ch the c upellati on was c arr i ed on .

S ECTI O N ON C—
D S ECT IO N ON E F
“
-

FIG 64 2
. Fre e
' ‘ ' ‘ ' ' ' ‘ ' ’ ’
1 o l 2 s I s e 1
'
s e to

FI G S 64 0 to . 644 — Old E ngli sh Cupelli ng furnace .

2 79 . Furnace — Th i s has undergo ne

ori gi nal English many changes fromth e

furnace as descri bed by Percy Fi gs 640 to 644 rep resent one for mof cupelling
I
. .

f urnace whi ch was commonly used i n Ameri can r efini ng works The ver ti cal .

sec t i o n ( Fi g 64 1 ) shows th e gener al constr uc t i o n of the f urnace wi th fire

.
,
.

place a v er ti cal flue b and space c between firebri dge wall d and
, , , , , , , ,

I B erg H itttenm Z
. 89 L 1 8 7 ; E ng M i n J
. .1 89 1 LII 5 7 1
,
1 1 , ,
. . .
, , ,
.

“
I
Metallurgy of Lead, ”
1 78 .
604 M E TALLURGY OF LE AD

enti r l g e en th of the li tharge slo t In such a case the suppor t for the t ools i s
a -
.

speci al cross mm -
bar (S ki me
i ng bar) let i nto the bri ckwork , or fastened in so
o ther co nveni ent manner .

Thi s f urnace wi th worki ng door at the S i de has thr ee di sadvantages Th e .

draf t sucks in ai r thro ugh the worki ng door and cools the li tharge flo w i ng from
the f urnace h enc e a tem perature hi gher than necessary for c upellati on has to be
,

mai ntai ned i n order to keep the li tharge gutter hot ; the size of th e furnace is
und uly li m i ted and wi th i t th e rate of cupelli ng ; the di rec ti o ns of flam e and

blast bei ng at ri gh t angles to one ano th er causes an i rregular tr avel of the li th ,

arge and wi th i t a li k eli hood of p ellets of b ulli o n bei ng carr i ed off

, .

Si nce th e advent of the Plat tner m odificati on 5) of th e G e r m a n c upelli ng

f ur nace the Plattner pri nci ple of constr uc ti on has been app li ed to the E ngli sh
,

f urnace Such a f urnace i s the one r epr esented i n Fi gs 64 5 653 wh i ch was

.
— .
,

i n Op er ati on at th e works of the Pueblo Sm elti ng Refini ng Co Pueblo Colo .

,
.
,

unti l the refini ng depar tm ent w as closed The si de elevat i on ( Fi g 685) and . .

plan ( Fi g 686) sh ow the general construc ti on of the furnace Fro mthe grate
. .
,

a work ed w
,
i th undergrate blast the flam e passe s thro ugh a narrow flue b , ,

(3 ft w i d e
.
) o n t o an d a cro ss t he
,
hear th c (5 ft w i de i n cr e as i ng to 5 f t 3% ,
.
,
.

ascends i n the ver ti cal flue d ( 2 ft 6% i n wi de) r etur ns thro ugh the h ori zontal ,
. .
,

flue e ( 2 3 in square) and th en descend s thro ugh f ( of sam

,
. e si z e ) i nto a m
,
ai n

flue underground Ai r for cupelli ng i s deli ver ed on to the hear th by the wa ter
.

cooled tuyeres i and i on ei th er si de of the firebri dge The br i ckwork of the

,
’
.

fireplace i s pro tec ted on the hear th side by a heavy casti ng g the o ther three , ,

si des are str eng th ened by hor i z o ntal rail s h and h laid i n the bri ck work and ,
'

sec ured by buckstays and ti e ro ds The si de w alls of the h ea r th are i nclosed -

.

by a heavy casti ng j the flange of whi ch 9 ( Fi g 64 5 646 and , ,

suppo r ts ,
.
,

th emand for m s at the sam e ti m e the co mp ass r i ng for t h e te st T he b ack of t he -

.

casti ng i s let i nto the bri ckwork of the fireplace i ts si des are sup por ted by the ,

buckstays k and i ts front by the legs I The flue e rests on i ron p lat es m
, , ,
.
, , , ,

whi ch are suppor ted by longi tudi nal rai ls n ; th ese are carr i ed by th e trans ,

verse rai ls a whi ch are bol ted to the flanges of two p ai rs of buckstays h and
, , , ,

by the br i ckwork of the flue f The flue i s bo und wi th angle i rons and ti e ,
.
-

rods The test ( Fi gs 64 5 64 6 64 7 649 and 6 50) consi sts of an oval r i ng r of

. .
, , , , ,

boi ler i ron streng th ened at top and bo ttomby flanges s and bound at the fro nt
‘

, , ,

by a loop shaped band of i ron I t rests on a cast i ron bed plate t I ts manner
-
.
- -

,
.

of supp or t i s shown i n Fi gs 652 and 653 Two rai ls AA run along the bo tt om . .
’

of the test ; at one end they rest on the ro unded bar B sup p or ted by a pai r of , ,
’
j ackscrews at the o th er they are h eld i n place by the looped ro ds RR sus
, , ,

pended fromthe yoke Y whi ch i s connec ted wi th a second yoke Y by means , , ,

’
,

of the ri gh t and left hand scr ew SS By tur ni ng the wheel W the front of the
'
-
.
, ,

test can be rai sed and lower ed w i tho ut difi cul ty I nto th e loop at the front .

fi t s the c ast i ro n br east j ack et ( Fi g -

whi ch rests on the cast i ro n bed -
.
-

plate t ( Fi gs 64 5 The test i s not water cool ed but i n order to pro tect
°

,
.
,

the fi lli ng m ateri al fro mthe corr o si v e ac t i o n of the li th arge a pai r of w ater ,

pi pes (10 and w Fi g 64 7) i s i mbedded i n i t ’

,
. .
606 ME TALL URG Y OF LEAD
 DE S I LVE RI ZA TI ON OF LE AD B ULLI ON 607

Drawi ngs of o th er f urnaces smaller i n si ze and used i n cyani de plants rather ,

t h an i n lead refineri es have been p ubli sh ed by W ei nberg Smi th M unroe

‘
,
I I
, , ,

C lark , and Stanwood .

I

LO NGIT U DINAL S ECT IO N A B -

FIG 662 .

FI G S 66 1 to . 664 — . D etail of cast i ron bed p la te of Fi g -

. 657 to 660 .

2 80 . whi ch ori gi nally consi sted of an oval frame

Test Ri ngs — The test ,
of wro ugh t i ro n ( 4 M i n wi de }6 i n thi ck) filled wi th bone ash has under
-
.
,
.
-

gone many changes in constr uc ti on manner of sup por t and filli ng mater i al , ,
.

I n Fi gs 665 666 and 667 i s shown a cast i ron test i r esti ng on a Rho des
.
, ,
-

, ,

l
S ECT IO N ON A E '

S ECTIO N ON C D ‘

S ECT IO N O N G H -

FI G 66S . FIG 666 . FI G. 667

FI GS . 665 to 66 7 — Cast i ron test
.
-
on Rhodes ca rri age, N ati onal W orks South Chi cago Ill .
, ,

test c arri age co c v bo tto m cast i ron pattern of the cavi ty

. I t has a n a e and a -

on th e i nsi de bo th of wh i ch w ill be di sc ussed f ur th er on

, The test r i ng i s .

rec tangular i n p lan and h as ro unded corner s I t fi ts i nto th e c up elli ng .

furnace sho wn i n Fi g s 64 0 644 Wh en i n p lac e i ts upp er surfac e wi ll be

— . .

I
Tr A ustral I nsti t
. . . Mi n . E ng , . 1 90 1 , I, 1 67 .

I
E ng . Mi n . J .
,
1 9 1 3, X CV, 603 .

I
Op . ci t .
,
1 1 37 .

I
Tr I nst
. . , M i n M et . .
,
1 91 2 -
1 3, XXI I , 68 .
608 M E TALLURC Y OF LE AD

on a line wi th the upper ri mof the co mpass ring p ( Fi g I n fro nt i t ,

.

has a 3 i n slo t j whi ch i s clo sed wh en the fi lli ng m

-
. ater i al form
, ,
i ng the h ear th
i s b ei ng ram med i n The r ec tangular formof test ofiers a larg e surface for
.

o xi dati on and therefor e more lead can be c up elled on i t th an on an oval

,

hear th .

Fi gs 668 6 70 repr esent an oval cast i ron test ri ng havi ng a hor izo ntal
.
- -

flange a When i n p lace the up per si de of th i s wi ll be close to or i n contac t

,
.
,

wi th the lower si de of the co mpass r i ng f ( Fi g and th e upp er edge Of th e ,

.

FI G 671
.

BOTTO M DO W N W ARDS
FI G 668 .

FIG 674. .

Outl et

Fi ll i ng
1 Pi p e i nl et ELEVAT ION

BOTTO M UPW ARDS FIG 67 S

.

FI G 669 . FIG 67 3 .

FIGS . 668 to 6 70 .
—Oval cast i ron test
-

,
Pennsylvani a Lead Co .
, Carnegi e, Pa .

FI GS . 6 7 1 and 672 — Front . of s t,

te water cooled i n part
-
.

FI G . 6 73 — Test wi th si des
.
p rotect ed by w ater i n cooli ng p i p es -
.

FI G S . 674 and 675 — Stei tz . water j acketed test

-
.

test r i ng i tself w i ll be i n li ne wi th the upp er edge of the co m pass r ing th us ,

maki ng the di stance between the roof and the surface of the lead as smal l
as po ssi ble The test ri ng pro tr udes over th e hor i zontal flange at c form
. i ng ,

a loo p d In tam
,
pi ng i n the filli ng materi al the loop i s no t fi ll ed i n
.
,

order that th e li th arg e overflowi ng fro mth e hear th may pass through i t into
the li tharge p ot below ; th us any co ntac t between h ot li tharge and i ron fram
-
e

i s avoi ded Across th e bo ttomof the test ri ng are four cast i ron arm
. s e -

, ,

to hold the filli ng i n p lac e .

Wi th bo th tests the corrosi ve ac ti on of the li tharge very soo n eats out the
filli ng especi ally at the front, and i n a co m
, p ar ati vel
y shor t ti me th e test has
6 10 M E TALLURGY OF LE AD

281 Test ri ng Supports

- —
of bringi ng the tests i nto posi ti o n
The . manner
and fixi ng th emth er e h as undergone var i o us changes The old m ethod co n .

si sted i n dri vi ng fo ur iro n wedges b etween the bo ttomof th e test r i ng and tw o

transverse bar s the ends of wh i ch wer e i nser ted 4 i n below the test fram
, e .

i nto the firebri dge wall d and the flue wall c ( Fi g I t is not m ,
uch used, ,
.

no w .

So wedges are sti ll r etai ned to adj ust th e large test frame represented
meti m es

i n Fi gs 674 and 675 . Thi s i s p laced on tw o 9 i n br i ck walls r unni ng alo ng th e

.
-
.

firebri dge and flue walls I t i s then rai sed to the h ei gh t of 1 2 i n and fo ur
. .
,

p i l lars ea ch thr ee
,
br i cks h i gh are p laced b enea th th e bed p la te wh i ch br i ng s ,
-

i t up nearly to the com pass ri ng By then dri vi ng flat wedges between th e .

bed plate and the bri ck posts the test i s adj usted to i ts final po si ti on
-
Am o re .

common way wi th sm all tests i s to use j ack scr ews wh i ch are sati sfac tory if ,

the entire h ear th i s m ade acc essi b le as i n th e m o dern cup elli ng f ur nace wher e
the h ear th walls rest on cast i ro n sup por ts The scr ews 1 8 i n lo ng and -
.
,
.

FIG 676 .
I z a 4 6

S cal e of Feet

FI GS 6 76 to. 6 78 — Test
.
-
carri age of Frazer Chal mers .

. meter work i n tw transver e bar plac d in beneath the te t ri ng

i n i n di a , o s s e 1 2 . s .

They ar i milar t cew d i n Fi g 6 79

es The te t ri ng r e t n a c a t i ro n p lat
o s s, ,
. . s s so s -
e

i nto wh i ch the poi nts of the fo ur screws are set Fo ur screw s are also fo und .

i n co nnec ti o n wi th a test carr i age as shown i n Fi gs 676 6 78 — H er e t he t est ,

. .

i s easi ly bro ugh t i nto po si ti on and th en rai sed by m eans of th e screw s and ,

bro ugh t up close agai nst the compass ri ng .

Wi th the thr ee arrangements descri bed the test when once p laced i s i m , , ,

movably fixed while the cup ellati on i s proceedi ng Fur ther when the furnace .
,

has becom e hot th e tur ni ng of the fo ur scr ew

,
s so m eti m es pr esents di fli culti es ,

wh i ch have been largely overcomeby more perfec t air cooli ng -

.

Rep laci ng the tw o fr ont scr ew s by a suspensi on or sup p or ti ng dev i c e wh i ch

can be r ai sed or lo w ered has overco m e th e fixed charac ter of th e older tests .

The Lynch test supp or t i s r ep r esented i n Fi gs 6 79 and 680

l
Th e te s t . .

p l ate e sh o w
,n bo tt o m
, s i de up i n F i g 680 has at th e b ack t h e t wo s ock e ts for .
,

the poi nts of the tw o b ack scr ews d ( Fi g Tw o supp or t bars c di v erg i ng ,
.
, ,

2 7 i n wh en extendi ng i n fro nt of the f ur nac e are clam

. ped to the front half of ,

I
Blake, Tr A I . . . M . E .
,
—
1 88 1 8 2 , x , p . 2 20; U S Patent No
. . . 2 75 2 3 2 , Ap ri l 3 , 1 8 83 .
 B E S ILVE RI ZA TI ON OF LEAD B ULL I ON 61 1

t h e p la te . When in place they are hook ed wi th the tur n buckles b -

, , to a tr iangle
ma d e of -
whi ch i s attached to a diflerenti al p ulley a hung fromthe
i n i ron,
.
, ,

ro o f . Wi th the p ul ley the test can be rai sed or lo wered qui ckly and evenly
t o r egulate the flow of li tharge w i tho ut al teri ng the d ep th of the li tharge gutter .

T h e co ntents of the test (r i ch lead or si lver ) can al so be p oured Wi th th e tur n .

b o l ts t he test can be ti l ted si dew ay s to counter ac t the ac ti on of the li tharge ,

s h o ul d th i s corrode one si de of th e h ear th m or e than the o ther .

T h e suspensi on suppor t of the Pueblo cup elli ng furnace has been shown i n
—
F i gs 64 5 6 53
. .

A no th er movable te t s ppor t whi ch has been adop ted by most refineri es

su , ,

i s th e one by F B F . .
—
Rhodes r ep r esented i n Fi gs 66 5 6 6 7 The test i s sup . .
,
.

r ted by a carri age o wi th i ts movable upp er frame ao Thi s rests at th e

'
p o , , ,
.

a Pul l ey Bl ock

FIG 680
.
S ca l e of F eet
FIG 6 7 9.

FIGS 679 . and 680 — . Lynch test -

sup po rt .

back on tw crews e and e work i ng i n the b locks d and d At the front i t

’ ’
o s , , , ,
.
,

i s supp or ted by the scr ew g worki ng i n the ri gh t arm a of the fram

, ,
e wh i ch , , ,

extends a shor t di stanc e i n fr ont of the f ur nac e and i s tur ned o utwar d sufli ,

ci ently for th e wh eel h to be to the r i gh t of the c up eller

, ,
By i nser ti ng a hook .

i nto one of i ts c i rc ular op eni ngs he tur ns the w h eel to ri gh t or lef t and th us ,

rai ses or lowers th e fro nt of th e f ram and wi th i t th at of th e t est

'
e aa I nto , ,
.

the upp er fram e cro ss beam are let i n wh i ch serve as supp or t for
"
bb b
'
s -

, , ,

the concav e bo ttomof the test If thi s w er e str ai gh t the surface of beam 0
.
, ,

would rep resent i n sec ti on an unbroken li ne two more b eams li ke I: and c ,

bei ng suffi ci ent to gi v e th e fram e the r eq ui r ed stabi li t y Th e wh eels O f .

the carri ag e are groov ed and tr avel on tw o rai l s r unni ng across th e spac e 6
,
 61 2 ME TALLURGY OF LE AD

( Fig . th us all s hifti ng of carri age to ri gh t or lef t when placed ,

in correct

po si ti on voi ded ,
is a .

Th e suppor t at the back by scr ew s e has the di sadvantag e th at wh en th e , ,

frame has to be lowered there before the carri age is taken out much di fi cul ty ,

i s experi enced i n turni ng th e screws To avoi d thi s the tw o screws e hav e been .
, , ,

replaced by two pi vo ts whi ch fi t i nto ci rcular openi ngs of two blocks fastened
to the beam s as shown i n Fi gs 6 54 6 56 — When the frame r esti ng at the . .
,

back on these two pi vo ts and suppor ti ng the test has been wheeled int o i ts ,

corr ec t po si ti on and i s to be rai sed thi s i s done by lifti ng i t a fewinch es wi t h a ,

crowbar or j ackscr ew and placi ng two U shaped casti ngs of the correc t hei gh t -

aro und the pi vo ts On wi thdrawi ng or lowering the crowbar the fr am

. e si nks ,

on the casti ngs wh i ch th en suppor t i t , When th e test is to be exchanged .

,

the fr am e i s agai n sli gh tly r ai sed t he tw o U shap ed casti ngs are r em ov ed

,
-

and the fr am e i s slowly lowered wh en i t wi ll agai n be supp or ted by the p i vo t s ,

.

The test ri ng i s then sufli ci ently low for the carri age to be wi thdrawn from
under the co m pass ri ng .

Ano ther m ovable sup por t wi th speci ally constructed test ri ng has been
cons truc ted by Roesi ng and i s used at Tarnowi tz Si lesia
l
, ,
.

Movable tests are i n much favor wh en the test ri ng i s no t water c oo l ed -

i e wh er e the lev el of the lead i s grad ually lowered by c ut ti ng deep er t h e

. .
,

li tharge gutter ; wi th test ri ngs th at are enti r ely water j acketed th ey h ave no t
been used unti l lately .

Wh atever test suppor t may be i n use care should always be taken to plaster ,

over wi th clay the upper surface of the ri ng so as to pro tec t i t agai nst co m i ng in ,

di rect contac t wi th the flam e and at the sam e ti m e to prevent the ai r from ,

rushi ng i n b etween co m pass ri ng and test ri ng .

2 82 H earth . Materi al The r equi rem

— ent s th at the hear th m a terial

sho uld f ulfill h ave b een gi ven on p age 5 6

9 T h e l ea d i n g m a te ri al s a r e t he .

followi ng
1 B one ash
.
— Th i s m ateri al w
-
. as used or i gi nally i n the E ngli sh c upelli ng

furnace I t i s sti ll used i n some E ngli sh plants but has been gi ven up i n most
.
,

refiner i es on acco unt of i ts co st and the fac t that i t i s not well sui ted for large
tests The bone ash i s gro und to p ass a 2 6 m
. esh scr een m
-
oi stened wi th wa ter -

wh i ch may or not contai n p earl ash amo unti ng to 2 % per cent of th e p re .

p a r e d bo n e ash T h e m o i-
st ene d m a
. te ri al i s r am m ed i nt o th e t es t fr a m e a n d -

the cavi ty scoop ed out i n the sam em anner as wi th the l i m esto ne clay m i x t ure -

detai led b elow .

2 Li m
. estone clay — A m i xture of 3 vol of li m
-
estone and 1 2 vol of clay
. .
-
.
,

dependi ng upon the bi nd i ng power of the lat ter i s ground thro ugh a 1 2 mesh ,
-

scr een .

In filli ng the test r i ng th e m ixtur e i s m oistened as show -

n i n § 2 77 and then
, , ,

tam p ed i nt o th e ri ng So m e w ork s b ea t d ow n t h e m as s
. i n t hr e e se p ar a t e la y e rs ;
o thers add the necessary mater i al all at once and begi n then wi th the tamp i ng .

If the ca st i ron test r i ng ( Fi gs 668 670) i s to be filled a p i ece of wood havi ng

- — .
,

I
Berg H i tttenrn Z 1 883 X LI I 577 ; E ng Mi n J
. . 1 884 XXXVII 4 1
.
, , , . .
, , .
6 14 ME TALLURCY OF L E AD

and 666, i t i s di fli cult to lay the

as bri cks so closely that no lead wi ll pass out
of the hear th through the joi nts .

When a test i s filled i t has to stand for fortni gh t and longer i n a warm
, a

place ( usually the cupelli ng room) to dry Thi s i s essenti al as the filli ng is-
.
,

li kely to crack if used too soon af ter i t has been p ut i n Before i t i s to be used i n .

a cold f ur nace a sm all ch arcoal fire i s m

, ad e on i t I n a warmf urnace th e fire i s .

kep t low for 3 or 4 hr af ter the test i s i n place . .

2 83 Th e Blast .
— The blast w as or i g i nally produced by a steamjet T hi s .

has gi ven w ay enti rely to a blo w er The m ach i nes i n com mon use are the Baker .

and Roo t blowers and the S turtevant fan ; blower and engi ne are usually sup
,

por ted ou the same bed plate The pressure of the blast i s about 4 oz p er sq -
. . .

in . The blast pi pe i s of sheet i ron and about 3 i n i n di am

-
eter I t i s frequently
-
. .

fitted i nto a cast i ron nozzl e som eti m es w at er cooled whi ch d eli v er s the ai r
-

,
-

through an ap er tur e 4 i n long and M i n wi de Thi s i s better; than si m

. ply . .

flatteni ng the end Of the sheet i ron pi pe -

.

2 84 Th e Tools .
— Th e tools r eq ui red by the c up eller are few: tw o rods ( 7 ft .

long of ,
i n i ron) bent to a book ; one chi sel po i nted bar ( 7 ft long of 94 i a
-
.
,
-
.
, ,
-
.

i ron) ; one saw( 9 i n long i n wi de 2 i n deep) at tach ed to a handle ( 6 ft

.
,
.
,
.
,
.

long of M i n i ron) to cut down the breast ; one fire hook ( 1 0 ft long of p i n
,
-
.
,
-
.
,
.

i ron w ,
i th a 4 by 1 0 i n h ead) ; one scoop ; one ladle ; 1 0 b ulli on m
-
. olds or silver
molds and three or more li tharge b uggi es havi ng small ket tles ( 1 3 i n i n dia m
,
.

eter and 8 i n d eep ) to hold the li th arge

. .

2 85 M ode of Operating
.
— Wh en the test i s i n p lace and well warm . ed the ,

tem perature of the furnace i s gradually bro ugh t to a dark red and so me lead -

i ntroduced thro ugh the front and m el t ed down When this has become a .

cherry red the blast is p ut on and cupellati on star ted N o di s ti nc ti on is made

-

, ,
.

between dross ski mmi ngs and li tharge as i n the Germ

,
an c upella ti on
, T he , .

li th arge i s made to run 03 at the front and fresh lead i s suppli ed fromthe back , ,

wh ere one or two small bars pro tr udi ng thro ugh Openi ngs into th e furnace are
melted down at such a rate as to keep the lead i n the test always on the same
level The li tharge i s collec ted i n a cast i ron p ot r unni ng on wheels W i t h the
.
-
.

large furnaces i n common use today an or di nary slag p ot wi th a loose central -

par ti ti on wall has rep laced the small li tharge p o ts The obj ect of the par ti ti on -
.

i s to faci li tate the break ing of the cone of li tharge The li tharge p ot w as at one .
-

ti m e r eplac ed by a w ater bO x Thi s has tw o advantage s I t red uces the t em

-
. .

p e ra t ure for th e c u p eller an d pr e sen ts t h e l i th arg e i n a g ra nu l ate d for m w h i ch ,

i s eas i ly handled and sam pled I t has however the di sadvantage th at a .

, ,

cupel carri age canno t be used and that i n the blast f ur nace there i s m
-
or e loss
,

i n lead and si lver w hen granular li tharge i s charged than if i t i s i n l um p form .

Granulati ng has been abando ned .

Wi th a stati onary i ron test ri ng the li tharge i s run ofi through a gutter cut ,

i nto the li ni ng I t i s not of ten that one gutter alo ne serves for th e pas sage
.

of the li th arge; generally there are three and often four opened one af ter the ,

o ther to prevent excessi ve corro si on A movable test gi ves an addi ti onal mode .

of regulati ng the flow of li tharge by loweri ng and rai si ng the front W i th the .
 DE BILVE RI ZA TI ON OF LE AD B ULLI ON 61 5

S tei tz water j acket test t he flow of the li tharge i s regulated only by the
-

q u a n t i ty of t he l ea d th at i s mel t ed ofl fro m th e b ars at th e b a ck of th e f ur na c e .

T he g utter can be closed for a shor t ti m e by allowi ng li tharge to acc um ulate

t h er e or w i th a pi ece of clay
,
.

Th e flow of the li tharge i s so r egulated that abo ut one half th e surface of the -

lead remai ns cover ed The for mer practi ce of cupelli ng and fining in the sam . e

f urnace has been abandoned at all large works At present i t i s common to .

conc entrate the b ulli o n to 60 or 70 p er cent of Ag on one test and to fine i t i n a .

sep arate f ur nace For thi s concentr ati ng work the water j acket test i s excel
.
,
-

lent as i t can be run by an i nexperi enced man wh er eas j udgment and practi ce
, ,

are necessary w i th a test where the li tharge g ut ter has to be regulated by the

c upeller By th us di vi di ng the cup elli ng i nto the two Operati ons of concentrat
.

i ng and fini shi ng a sm all er num ber of experi enced and reli able cupellers i s
,

necessary Wh en the b ulli on i s concentrated to the desi red degr ee i t i s ladled

.
,

o r po ur ed o ut and go es t o the fini shi ng f urnace and the concentr ati o n fur nace ,

i s agai n filled Th us a conc entr ati ng f ur nace r uns constantly

. After a cer tai n .

tim e th e bo t tomb eco m es too th i n and h as to be exch anged A test r i ng filled .

wi th li mestone clay if used 4 or 5 hr daily for finishi ng lasts onl y 30 days ; a

, .
,

c ement test used for the same purpose lasts months A water j acket test filled
-
.
-

wi t h li mestone clay used for concentrati ng lasts about 60 days A test ri ng , , .

fi ll ed wi th cem ent and used for co nc entrati ng and r efini ng lasts 7 day s .

The fini shi ng i s always d one on a test havi ng an iron test ri ng The op era .

t i o n i s the sam e as i n c onc entr ati ng but usually not co nti nuo us Toward the , .

end wh en th e si lver l ead alloy becom

, es l ess readi ly f usi ble th e tem
-
perature has ,

t o be consi d erably r ai sed Wh en th e si lver has becom e sufli ci entlyco nc entrated

.
,

t h e ad di ti on of r i ch b ulli on i s stopp ed The last li tharges are drawn OE and .

th e t est r em ai ns al m ost filled wi th crude si lver whi ch has nowto be fined I t i s , .

not of ten th at the br i gh teni ng i s seen Sam p l es tak en fro m th e m e ta l ba th show .

how far the cupellati on has progressed The fini ng consi sts usually i n exposi ng .

t he silv er for som e ti m e to the ac ti on of th e h eat and th e blast Bone ash i s

'
-
.

so m etim es gi ven i n sm all q uanti ti es to absorb the i m puri ti es that float on the
surface or h ave collec ted on the edge At som e works ni trate of soda i s used .

i n the f urnace to m ak e the si lver at least 99 7 fine as th i s has b ecom e the standard ,

below wh i ch fine si lver should not go The ni ter i s spr ead on the si lver a shovel .
,

ful (abo ut 1 2 lb ) at a ti m e To prevent the soda fromcorrodi ng the filli ng of

. .

th e test ri ng som e r efiner s spr ead finely gro und br i ck over the ni ter
, The .

sl ag floati ng on the si lver i s r em

, oved only when the si lver i s fine and ready to ,

be cast i nto m olds Abo ut 1 5 shovelfuls of ni ter are req ui red for
. oz .

of si lver .

In thi s connec ti on the beh avi or of tellur i umi s of i nterest Whi tehead and I
.

Ulk e state that i n th e second refini ng of doré si lver (ob tai ned i n worki ng the
2

ano de m ud fro man elec troly ti c copp er refini ng plant) w i th ni ter the r esulti ng ,

sl ag contai ned as m uch as 2 0 p er cent Te i n the for mof tell ur i te of sodi um . .

I
J Am ChemS oc 1 89 5 XVII 84 9
m
. . .
, ,
.
,

I E ng . Mi n . J .
, 1 89 6, , 51 2 .
6 16 ME TALLURGY ’
OF L EAD

I t i s very di fli cult to re ll uri umfromthe si lver owi ng probably move all the t e ,

to the presenc e of Cu N i ter alone does not appear to m eet the need ; r efiners
.

are often forc ed to blow ai r thro ugh th e si lver for hours at a time to get ri d of

all the Te .

A mor e si mple procedure whi ch i efiecti ve and in common u e i n E uropean

, s s

plants we s sas ll a i n om
s e work i n th e Uni t d Stat
e es sis to add om
s e fr e h l ad
e ,

to the doré si lver when thi s i s abo ut 9 90 thousand th s fine , A charge of .

oz . doré silver req ui res abo ut 1 000 lb of lead whi ch i s added i n three or four .
,

por ti ons The li tharge form

. ed oxi di zes the Cu and w i th i t the Te and Bi ,

whi ch adhere so strongly to th e si lver .

Tho ugh i t i s di fi cult to rem ove Te the metal Se i s readi ly oxi di zed and ,

volati li zed and i s fo und i n the flue dust The dust of ten forms the raw -
.

materi al for the producti on of seleni um

,

I
.

As r egards copper the investi gati o ns of Mathewson and Stokesbury are ,

I

of i nterest Th ey find that Cugo i s readily soluble i n Ag when molten and

.
,

prac ti cally i nsoluble when soli d The freezi ng poi nt curve shows a eutec ti c .
-

poi nt at 94 5 C ; the eutec ti c i s comp osed of Ag

°
. and cu. o p e r c ent A .

com pari son of calculated values wi th those ob tained by experi ments i ndi cates
that di ssolved Cugo i s ei th er di ssoc i ated or r eac ts upon Ag as shown by Cu30
+ 2 Ag 2 Cu+ AggO A Ag Cu all oy wi th li t tle Cu m
fi
— . el ted and all ow ed t o ,

soli dify i n air sh ow s th at the Cu occ ur s as CU zO between gr ai ns of Ag; hence the

, ,

Cu i n all c up ell ed silver m ust be present as Cu30 and no t as Cu as has been

sup po sed .

The i ndi cati ons of fine si lver are : tha t the surface i s sm oo th and clean; that
sti rri ng fai ls to br i ng i m p uri ti es to the surface; that a tool held over the si lver
i s clearly r efl ec ted i n i t ; that a sam ple tak en by i nser ti ng a rod w i ll show no
spo ts wh at ev er on the surf ac e and h av e a p ur e si lv er w hi te color ; and t hat a , ,
-

sam ple taken wi th a spoon wi ll sp ur t whi le cooling al though thi s i s not a good ,

test Som
. e r efiner s cast a sm all sam ple bar exam i ne the surface wh i ch sh o uld -

, ,

be sm oo th and the frac ture whi ch shoul d be finely granular and show a silk y
, ,

luster ; test for malleabi li ty by hammeri ng etc The only way to know defini tely , .

how the fini ng i s progressi ng i s to make an assay Thi s i s done i n the dry way .
,

by wei ghi ng out twi ce gramof a gr anulated sample and I4 gramof c p si lver . .

as a ch eck and c up elling the thr ee sam ples wi th the same amount of lea d on
m
,

three c up els placed i n a row i n the m u e A second assay half an hour later .

wi ll show wheth er any progr ess has been made An assay i n the wet way wi th .
,

potassi umsulphocyani de usi ng ferri c sulphate as an i ndi cator wi ll gi ve the

-

, ,

sam e r esul t m ore q ui ckly than cupelli ng .

An analysi s of governm
I
ent sil ver ( assay si lver ) showed : Ag Cu
Pb Au As Sb Fe Zn tr ace Te p er ,

cent .

When the si lver i s fine that i s when i t ranges between 997 and 99936 i t , , ,

I
See H of man , Copper, 1 91 8, 5 1 8 .

I
I nternat Z t . . Metallogr .
, 1 9 1 4 , v, 1 93 .
I
B rass World, 1 906, n, 389 .
61 8 M E TALLURGY OF LE AD

s hown i n Fi gs 657 —660

whi ch holds 5 tons lead bulli on there are cup elled
.
, ,

i n 2 4 hr fro m5 to 6 tons wi th an oi l consum

. p ti on of 2 80 gal .

I t i s advi sable to have 8 hr shifts for c upellers to prevent thei r becom -

. i ng ,

leaded .

T e co ce tr a
h n n t i n g o 1 000 lb
f f c n t b u ll i o n n by 8 —i n t t
O 7 p
0 e r e o a 33 . 2 e
s -
. .
,

5 i n .d eep an d r e fi n i ng of, t h e r es u l t i n g si lv er ( sa y 1 2 000 o z s i lv er ) l a s t s a b o u t , .

,

5 h r r
. eq,
ui r es o n e m a n a n d a bo u t 1 5 00 lb of, n u t co al W h e n t h e . .

fini shi ng fur nac e i s stop ped for a day or tw

-
o th e fire on th e gr ate is kep t go i ng ,

i n order that the tem peratur e of the test m ay not sink b elo w a dull red ; -

charcoal i s of ten kep t aglow on the test as i t makes i t again porous wh en i t is ,

much soaked wi th li tharge .

2 88 Loss — The loss of Pb i n c up elli ng i s generally gi ven as bei ng 5 p er cent ;

. .

th at of Ag i s under 1 per c ent presup po si ng that the unco rr ec ted assa y to .

,

be the basi s of c alc ulati o n ; the loss i n Au i s ni l Rose fo und th at Au bega n to

I
.

becom th at th e lo ss am
°
e volati le j ust below 1 1 00 C ounted to p e r c e
. n t
,
.

at 1 and that standard cop per gold w as m ore volati le than p ure Au -
.

M ostowi tsch and Pletnefi on the o th er hand fo und that no Au was vola ti li zed
I
, ,

at th ese tem p er a t u r es

m
.

2 89 Com p ar.i s o n o f G e r a n a n d E n gli sh C u p e lla ti on — A c o m p a r i so n o f

the tw o m etho ds of c upelli ng leads to the conc lusi o n that the Ger m an m eth o d i s

by far the mor e expensi ve for p urp o ses for whi ch c up elli ng i s gener all y used
today Altho ugh i t form
. s li th arg e m ore rapi dly because the hearth i s larger , ,

i t produces only a com p a r a ti v e ly s m a ll a m o u n t of s i lv e r as t h e p rod u c t of o n e

op erati on To r emove the si lver the f urnace has to be cooled and the h ea r th
.
, ,

tor n out and r eplaced by a newone Thi s tak es ti m e th us neutrali zi ng the .

,

advantag e of th e q ui ck form ati on of li th arg e and costs m uch labor f uel and , , ,

materi al includi ng a large amount of hear th material, wh i ch has to be smel ted

,

i n th e blast f ur nace for every c up ellati on I n the E ngli sh c upelli ng furna ce .

,

esp ec i ally w i th i ts Am er i can m o di ficati ons a c upel bo ttomlasts for weeks ; , .

the process i s therefore less i nterr up ted and th us m uch exp ense for labo r f uel , , ,

and m ater i al saved but i t has the dr awback th at t he li tharg e i s always m

, o re ap t

to be r i ch and h p ure .

A Germ an c up elli ng f ur nac e m i gh t be in place wh en the r esul t ing li tha rge

i s to be sold as such and i s ther efore req ui red to be p ure and poor i n Ag but
, , ,

modern Amer i can c up elli ng fur naces are of ten as large as the older German ,

h ence thi s consi der ati on has lost i ts former i m por tance The E ngli sh f urna ce .

w i th Ameri can i m p rov em en ts i s d ec i d e dly pr efe r a bl e if t h e b u l li o n to b e ,

cupell ed i s so ri ch that the resul ti ng li tharge i n any case would run too hi gh in , ,

Ag to be sold as such I n thi s case and i t i s the com . mon one to day i t i s not ,
-

of much co nsequence wheth er the li th arge be a li ttle poorer or r i ch er i n Ag 01 ,

i f i t be som ewh at contam i nated wi th i m p uri ti es as long as the advantages more ,

than m ake up for such defic i enc i es .

I
] . Chem S oc , . . 1 89 3 , L X III , 7 1 4 .

I
M et Chem E ng . . .
,
1 9 1 7, X
V
I, 1 53 .
 DES ILVE RI ZA TI ON OF LE AD B ULLI ON 6 19

BETTS PRO CE S S

1—
2 90 . Betts Process, General . Thi s
process is only elec troly ti c p rocess
the
of refini ng lead bulli on whi ch has been succes sful It i s i n oper ati o n at Tr ai l
.
,

B C ; E ast Ch i cago Ind ; Om

. . aha N eb ,
.
,
.
, and N ewCas tle on Ty ne E ngl and - -

,
.

O th er processes have ei th er been fail ur es , or have not gone beyond the labora
t ory stag e .

Th e process i s worked accordi ng to the m ul ti ple sy stemcom mon i n the

el ec troly ti c refini ng of copper Cast anodes of lead bulli on and lead cathod es
2
.

( of e l ec tro ly t i c l ea d ) c as t i n s h eet for m co nnec te d i n m u l ti ple are suspended , , ,

fro mcopper bars across an oblong vat whi ch i s charged wi th an electroly te ,

c ontai ni ng lead fluosili cate ( PbSi F s) and free hydrofluosi li c aci d (H zS i Fo) .

T he c urr ent enter s th e anodes passes through th e elec troly te to the catho des , ,

d i ssolv es the lead fromthe anodes and dep osi ts i t on the cathodes The i m ,
.

p u ri t i es wh i ch,
n ea r ly a ll a dh e r e t o t he und eco m po se d a n o d e s form the anod e ,

mud or sli me The catho de lead wi th the star ti ng sheet i s melted and cast i nto
.

bar s ; the ano de m ud r ecover ed from th e non corroded anode and coll ec ted ,
-

fro mthe bo ttomof the tank i s refined to recover pr eci ous metals Sb As Bi , , , , ,

C u and possi bly Se ; th e Te for wh i ch th ere i s no m

,
ark et at present goes to , ,

waste .

In the p roc ess the PbSi Fo di ssolved i n w ater aci d ulated w i th H zSi F. , i s i n
di oc i d i Pb d Si F
"
i o I h l c roly i S i F
"
i o r v l
'

p art ss at e nt o an o ns n t e e e t s s o ns t a e .

t o the anode, gi ve up th ei r charges to the anode and combine wi th an eq ui valent ,

am ount of Pb In the same manner the Pb i ons mi grate towar d the cathode
’

.
,

g i v e up th eir charges to the cathode and are deposi ted as metalli c lead In t e ,
.

al i t y the proc ess i s not as si mple as outli ned ; th ere occur si de r eac ti ons causi ng a -

dep osi ti on of Si 02 on the anode wh i ch sti ll lacks a sati sfac tory exp lanati on ,
.

Elec trolysi s causes Pb Sn Zn Fe N i and Co t o go i nto soluti on wh ile Cu , , , , , , ,

1
Betts, A G . .
, Lead Refini ng by Electrolysis , W iley NewYork , ,
1 908, General .

Bet ts , U S Patents, N os 7 1 3 2 77 and 7 1 3 2 78, Oct 9 ,

. . . . 1 90 2 .

Ulke, E ng M i n J 1 90 2 , Lxx rv, 4 75 . . .

Betts, Tr A. I . . M . E .
,
v, 1
1 904 , xxx r 75 .

Senn, Zt El ectroche . m 1 90 5, xx, 2 2 9 ; Mi n . M ag .

,
1 90 5, xrr, 7 1 ; Electroche mM . eta] . I nd .
,

m
,

1 90 5, , 272 .

W hi tehead M i nes , and M i nerals ,

1 90 5 , xxv, 2 85 .

Betts , E lectroche m M cl . . I nd 90 5, I II , 44 1
.
,
1 .

W olf W est , . Chem M et . .

,
1 90 7, ,
83 m .

M ardus G “D octorate .
”
T hesi s, Berli n, 1 908 , usi ng H B F q .
, ,

Bet ts, U S Patents, N os 89 1 39 5 . . . and 89 1 396 , June 2 3, 1 908 ; 9 1 864 7, Ap ril 2 0, 1 909 ,
T reat ment of Sli me .

Betts , M etall urgi e

909 , v1 , 2 33 ,
1 .

McN ab, U S Patent , N o 905 753, Dec . . . . 1 , 1 90 8, Recovery of Sb f ro msli me .

Foerster -
Schabe, Z t El ectroche . m .
,
1 9 ,
1 0 xvr,
2 79 , T reat m ent of Bi Ag -
.

Kern, M et Chem E ng , . . . 1 9 1 1 , lx , 4 1 7, Anode M ud .

M iller M i n , . E ng . World , 9 1 3 ,
1xx rx , 57
.

Th u mU ,
. S Pa tent N o
. . 1 09 88 54 , J une 2 , 1 9 1 4, Treat ment of Cu beari ng Bi -
.

S mi th , U S Patent N o . . . 1 1 66 7 2 1 , J an .
4, 1 91 6, Refini ng of Bi .

Rufi Braun, B er deutsch che

-
Gesellseh , . . m . . 1 9 1 4 , ccx rvn
’
,
64 6, Prep arati on of HF .

“ ”
m
See H of an, Copp er, 1 9 1 8, 4 9 1 .
620 ME TALLURG Y OF LEAD

Sb, As, Bi , Cd, Ag, Au, Se and Te r e ai n wi th the anode Of the etals that m . m
are di ssolved , Sn stands so near Pb i n the elec trolyt i c ser i es that i t i s dep osi ted

w i th the Pb According to Betts, th e s all a o unt of

l
.
p e r c ent S n i n m m .

th e ano des of Trai l B C went over to cathodes ; h c

, . bear .
, the en e Sn -

i ng lead b ull i on has to be sof tened before i t i s cast i nto anodes

The o ther m etals Zn Fe N i and Co stand well above Pb i n the ser i es and are
, , , ,

th er efor e not p r ec i p i tated fromthe sol uti on wi th Pb Of the m etals whi ch re .

main i nsol uble small amounts of Sb are li k ely to be carri ed over mechani cally to
,

the c athode esp ec i ally w i th a curr ent of hi gh densi ty ( 1 7 to 1 8 am p p e r s q f t ) . . .

and a warmel ec troly te (3 7 to 38 so that the cathod e lead m ay have to be

°

refined for a shor t ti me e g p oli ng wi th ai r i n a ket tle ,

i n order to rem
. .
, ove
them ; a ny Sn pr e se n t wo u ld b e ex p e ll e d fro m t h e P b b e for e S b .

2 91 Electrolyte
.
— The elec troly te contai ns from 7 to 1 0 p er cent Pb and
. .

from8 to 1 2 p er cent to tal fluosili c aci d (H 3Si Fe) ; the free H 3SiF. vari es from3
.

to 5 p er cent A co nveni ent factor to app ro xi m

. ate th e H 3Si F¢ i n com bi na ti on
wi th Pb i s to mul ti p ly Pb by Curves showi ng the el ectri c conduc ti vi ti es
of PbSi F, and H gSi F , have been gi ven i n Fi g s 30 and 31 To the electroly te . .

g elati ne i s added as a hot strong soluti on of glue to the amount of p e r c e n t i n .

or der to ob tai n a soli d deposi t 3

The dai ly addi t i on i n pr ac ti ce i s abo ut .

p er c e n t of t h e w .e i gh t of t h e elec troly te T h e e l ec t roly t e i s m a d e at t he w o rk s .

by allowi ng H F to act up on Si Oz to formH 3Si Fo and th i s to combine wi th Pb ,

or PhO or wh i te lead to produce PbSt Th e hydro .

fluori c aci d i s ei th er the com merci al produc t wi th 33 p er cent H F or i t is made .

, ,

at th e p lant by allo w i ng H gSO4 to act up o n fluorsp ar ( CaFg) The r eac ti on taki ng .

place i s exp ressed by C3 F3 + H 2804 = 2 H F+ CaSO4 Accordi ng to Ruff and .

Br aun th e process tak i ng p lace i s not as si m

‘
p l e a s i s g e n e r a lly h eld H e fo u n d .

th at the best yi eld 8 1 p er cent of the th eor eti cal w , as ob tai ned by usi ng 90 .
,

p er c e n t of t h e a m
. o u n t of th e H gSO 4 (p s gr ca ll e d for th e ore t i ca lly a n d . .

°
h eati ng for 3 hr to 2 00 C A horiz o ntal cast iron cyli nder t o by 4 ft fired
. .
-
.

from the bo ttom i s charged wi th CaFg and H gSO 4 As the reac ti on de .

velop s m uch h eat the fire has to be well r egulated ,

The li ber ated H F i s col .

lected i n tw o l eaden W o lf fl ask s connec ted i n ser i es I n the first flask i s fo und .

so m e H gSi F o wh i ch co m es fro mth e Si 02 of the Ca ; i n the second wh i ch i s ,

water cooled the H F i s condensed

-

,
.

The H F i s m ade to asc end i n a sm all lead tower filled w i th p ure sand ( Si og ,

99 5 p
. er c ent ) a t s u ch a r at e .th at i t d i ss olv es t h e S i 0 2 ; t h e ov e rflow i n g H zS iF .

i s conduc ted i nto an oblong box filled wi th granulated lead where there i s form ed

PbSi Fo; the sol uti o n i s ci rc ulated by m eans of a subm erged c entr i f ugal p um p
1
Treati se, p age 4 7
m wholly mechani cal
.

So e refiners hold that the transfer of Sb to the cathode i s not .

Senn, Z t Electroche . m .
,
1 905, xx, 2 2 9 ; Mi n Mag . .
,
1 90 5, x1 1 , 71 ; Electroche mM t . e I nd ,
m
. .

1 905 , 2 72

m 53 ;
.
,

Mathers and O ver man ,

Trans A . m El ct och m S
. e r e . oc .
,
1 91 3, xx 1 M et Chem E ng
. . .
,

1 9 1 3, x x, 2 85 .

M utscheller op ci t 5, x m 353
mh
, . .
, 1 91 ,
.

B er de . e . che mG . esellsch .
, 1 9 1 4 , cc, a
’
, 64 6 .
622 M E TALLURG Y OF LE AD

by 36 i n .
%
and 1 m th i ck
.
3 75 lb T h e,
a nwei ghs
od es ar e so m ewh a t t
.h i nn er
i n com p ar i so n w i th tho se used i n copp er r efin i ng as d ur i ng ele c t ro ly si s th e ,

large amo unt of i mp uri ty present adh eres to the anode and i ncr eases the
r esistance to the c urr ent If th e coati ng beco mes too thi ck i t fall s to the
.
,

bo tto mand i s li k ely to ca use shor t ci rcui ti ng ; f ur ther consti tuents of th e mud ,

are li k ely to go i nt o sol uti on or to be h eld m echani cally i n susp ensi on and to be ,

dep o si ted on th e c atho de .

S ECT IO N

Re movable

S ECT IO N E F -

F10 682 .

Fros 68 1 to 683 — Sta ti ona ry anode

. . mold .

Anodes cast i n open molds The up ri gh t Tr uswell closed mold used

are .
,
l

at first at Trai l w as unsati sfac tory as th e top s freq uently wer e p oro us
, , The .

lead i s cast fro mthe k et tle i n wh i ch the blast furnace p roduc t h as been freed
fromdross I t i s do ne by means of a si p ho n or a p ump deli ver i ng i nto mo lds
.

placed ei ther on a sta ti onary frame i n a three q uar ters ci rcle or on a ro ta ti ng -

table . A stati o nary m old has been shown i n Fi gs 68 1 683 The M iller ca st
— . .

i ng p lant w ,
—
i th ro tati ng tabl e i n use at Trai l B C i s show n i n Fi gs 68 4 6 8 5 ,
. .
,
.

E ng . Mi n J . .
,
1 906 , Lxxx 1 , 853 .
 DE S ILVE RI ZA TI ON OF LE AD B ULLI ON 623

T he leadi ng par ts are an oi l fired kettle wi th M i ller centrifugal p um g

-

a ro ta t
i ng table dr i ven by a m
, o tor thro ugh gear i ng and wormwheel wh i ch carri es -

t i l ti ng anode m olds and a latch tri p p er to i nver t the molds and dum
, p th e an od es
-

T he lead b ull i on fro mthe blast f urnaces i s po ured i nto tw

.

o k ettl es wh er e i t

cools ; i t i s drossed and pum

,

ped i nto the storage kettle of the mach i ne The

k ettle i s 8 ft 9% i n i n di ameter and 4 ft deep In the center i s the submerged
.

. . . .

c entri fugal pump whi ch deli vers the lead through the i ncli ned pi pe i nto a
horiz ontal branch provi ded wi th a r i ser and pi p e handle at the ends -

and a ti l ti ng d eli very p i p e i n the center The lead r ai sed

-
.

by the p um p flows under a gi ven h ead through the de

li v ery pi pe i nto the m old i f i n the po si ti on shown i n the ,

fi g ure As soo n as the m

. old i s filled the deli very pi p e i s ,
-

t ur ned up and th e l ead flows back i nto th e kettle

, In .

o r der to sec ure anod es of uni for mth i ck ness a sm all 4 leg ,
-

i ro n table wi th i ncandescent lam p ( not shown) i s placed

o n the em p ty mold When the lead has ri sen i n the mold.

t o the r equired dep th i t co m es i n contac t wi th the pol es ,

o f the lam p closes the elec tr i c ci rcui t and causes t he cur

, ,

r ent to pass thro ugh the lamp wh i ch suddenly bri gh tens .

I n p assi ng fromthe feed to di scharge end the lead i n t he -

molds i s sprayed and soli difies The anode i s dump ed . .

T he m old i s spli t under the sho ulder s and the lower p art
p i vo ted Th us i n ti l ti ng the lower p art of the mol d th e
.
, ,

s ho uld ers of the anode are released from th e m old ; the

ano de i s no t bent by th i s proced ur e The dum ped anodes .

are tak en from the d um per stand by means of a traveli ng

co mp ressed ai r lift and dep osi ted on to a transfer car
- -
.

T he m achi ne m akes o 1 5 1 casts p er hr . .

25 — b r w i gh i ng 8— l b and r eq ui res — h
5 4 2 0 a s e 9 1 1 2 3 4 p .
,
. .

2 94 Cath ode
.
— Thi s i s abo ut i i n larger all ro und .

th an the anod e At first the lead cathodes wer e plated

FI G 6 83a Tw
.
,
o . .
-

sh eet i ron; later elec tro d eposi ted sh eets of lead wer e used ; -

p ron g p y bar
r -
.

at pr esent th ey are cast wi th th e appar atus devi sed by J F . .

M iller Trai l B C and shown i n Fi gs 686 688 A slopi ng cast i ro n table

, ,
. .
,
.
-

.
-

car ri ed by an adj ustable steel frame has pi vo ted at the up per end a trough ,
.

T h e trough i s filled fro ma k et tle wi th cathode lead by m eans of a ladle and ,

t i l ted on to the table wh ereupon the lead flow s down the table ; m ,
ost of i t
so li di fi es i n a th in even pl ate and the r est r uns off the bo tt omor i s caugh t i n
, ,

t he gut ters placed on the si des The sh eets are tak en ofl fromthe table pi led .
, ,

and later wr ap p ed by hand aro und the cross bar s Three m en wi ll cast -
.

—
1 1 00 1 4 00 sheet s i n 6 hr .

An i m provement on the ori gi nal machi ne i s represented i n Fi gs 689 690 — . .

I t consi sts i n cast i ng f asteni ng lugs at th e sam e ti m e that the plat e i s bei ng

cast and i s acco mp li shed by provi di ng the lower par t of the i ncli ned table
,

wi th two tongues The lead flowi ng down wi ll formthree stri ps whi ch when
.
624 ME TALL URG Y OF L EAD

bent over a sti ck and welded each at two po i nts by an arc burner wi ll f urni sh ,

thr ee loops thro ugh wh i ch i s sl i pp ed the c0p p er cro ss bar The sh eets when -
.

removed fromthe table are flattened wi th wooden m all ets .

Instead of h avi ng tw o proj ec ti ng to ngues on th e pla te th e spac es occ up i ed ,

by th emhave been cut out e g the table 4 ft 4 i n by 2 ft 2 i n f urni sh i ng sh eets

,
. .
, ,
. . . .
,

4 ft 1
. i n lo ng h as.two slo,
ts 2 % by 6 % i n wh i ch be g
,
i n 5 i n fro m th e l o wer . .

edge of the table The lead flowi ng down th e table form

. s thr ee str i p s 1 1 94 i n .

lo ng as i t does not cover the par t of the table j ust below the slo ts
,
.

m684
F .

S ECT IONAL ELEVATION

F1 0 685
.

FI G S 684
. and 685 .
— Miller anode casti ng m
-
achi ne .

2 95 . Electrode Di stance — . Thi s is 1 94 36

—2 i n ; i n th
. e plants na ed i t m
ranges from2 }{ o to 2 % i n center to .
, center , and is about 1 % i n face to face . .

I n all refini ng work a di stance th at i s sm

, all decr eases r esi stance and i ncr eases

k w o utp ut but tends to cause br i dgi ng of sp ac e and th ereby shor t ci rc ui ti ng

.
,
-

wi th consequent loss i n amp ere efi ci ency; one that i s large increases th e re ,

si stance d ecr eases kw o utp ut but gener ally gi ves a bet ter am ere efi ci enc
, .
,p y
The prop er di stance has to be determ i ned for prevaili ng co ndi ti o ns .
626 ME TALLURGY OF LE AD

S IDE ELEVAT ION

F m689
.

'

a a ( in .

"

12 Long
FIG 690
.
3 H andles
PLAN
Frc s . 6 89 and 690 I
.
— mp rov ed cathode casti ng-
machi ne .

Fro 69 1 — Electrolyz i ng
. . vats i n two ro ws ,
T rai l , B C
. .
, 1 905.
 DE S ILVE RIZA TI ON OF LE AD B ULLI ON 627

bri ngs out the tendency of the elec troly te to forma heavy
i n Table 1 51 whi ch
mof a tank if the travel i s not sufli ci ently swift or i ts path is
l ay er on th e botto
not properly gover ned .

T AB LE 1 51 —
. Cracu mr ro n or E mm orm
FLo wTH RO U GH 1 4 T AN KS

FLo wT axoucn 2 T AN KS

Fro 69 2. .
-
E lectrolyzing vats, si de by si de, Trail, B C . .
, 1 906 .

The newtanks buil t of cement co ncrete wh i ch recei ves a coat

at Trai l are

of P and B pai nt ; the latter i s pro tected fromany ac ti on of the elec trolyte by a
layer of asphalt M i n thi ck The leadi ng features of the plant are shown i n
. .

Fi g 693 and those of the vats i n Fi gs 694 696

.
,
— The plant has 408 cells pro . .
,

d uces dai ly 1 00 tons refined lead and recei ves a current of 3000 3500 am —
, p at 90 .

volts The cement vats are arranged i n cascades wi th a drop of 3 i n between

. .

tanks .The elec troly te i s c i rc ulated thro ugh r i n hard r ubber p i p es wi th a -

.

flow of from4 to 6 gal p er m i n The p i pes deli veri ng and wi thdrawi ng the
. .

sol uti on of a tank are plac ed di agonally at t he end s so as to co unter ac t lay eri ng ;

th e wi thdrawi ng pi pes extend to 6 i n fromthe bo ttom Centr ifugal p um

-
ps of . .

copper rai se the electroly te to the head tank .

A tank 7 ft 4 % i n by 2 ft 6% i n and 3 ft 8 i n d eep hol ds 2 0 anodes and

,
. . . . . .
,

2 1 catho des wh i ch leave a bo ttomspace 2 0 i n deep ; the el ec trod e d i stanc e i s

,
-
.

23 40 i n T.he an od es 3 by 2 f t a nd M i n, t h i ck w ei gh 375 l b an d a s
.s ay Pb .
,
.
,

8
9 p er c ent a nd Sb 0.
3
— 1 p er c en t ; th e c a
.t hod e s 3 ft i n by 2 ft 1 i n. a nd ,
. . . .

i n th i ck wei ghi ng 1 50 lb are wrapped around copper cross bar s

.
, .
, x 1 in -

,
.
,

flattened at the ends ; th e busbars 3 X 2 i n are not i n contact wi th the con ,

.
,

crete walls but rest on 4 4 mwooden i nsulators coated wi th p arafli ne pai nt

,
1 .
628 M E TALL URGY OF LEAD

Fro . 69 3 —
. T ank house, T rail , B C
-
. .

CROSS S ECT IO N LO NGIT UDINAL S ECT ION

Fro 696
.
FIG- 695

h as 694 to 69
. 6 — E Iectrolyzi ng vats, Trail, B.
. C .
630 M E TALLURGY OF LEAD

The c urr ent densi ty mp p er sq ft cathode area the drop i n potenti al

—
is 1 4 1 6 a . . .
,

p er va t i s vol t .

E lec trodes are handled by an elec tri c crane a tank load at a ti m e; anodes ,
-

—
are exchanged every 5 days and gi ve 2 0 2 2 p er cent scrap cathodes every 4 —
5 .
,

— —
days The elec trolyte contai ns 4 5 per cent Pb and 1 0 1 1 per cent H , Si Fg
. . .
,

and has a tem

°
perature of 2 5 30 C
— .

The refinery of the U S M etals Refini ng Cc at East Chi cago Ind has . . .
, ,
.
,

2 08 vats arranged i n 52 uni ts of 4 cells ; i t works wi th a current of fro m54 00

,

to 5800 am p at 1 00 to 1 1 5 vol t
.s and prod uc es i n 2 4 ho ur s 1 00 to ns r efined ,

lead The Walker systemof arrangement of tanks i n uni ts of four shown in

.
,

j — s 4x
' '

CROS S S ECT IO N

FI G . 699.
— Electrolyzi ng vats, East Chi cago, I nd .

Fi gs 69 7 99 , i s i n op erati on for the 44 uni ts or i gi nally i nstalled

.
—6 . Th e new
-
m
round bo tto tanks, whi ch are replaci ng the older flat bo tto for -
m m ar s e also

of wood but of the Th umpattern

,
Thei r ch ar ac teri st i c s are that th ey do not .
l
,

carry th e elec trodes wh i ch are susp ended i ndependently and bei ng r eli eved
, , ,

frompr essure can have ro unded bo tto ms of stave cons truc ti on h eld together
,

wi th rod hoops The tanks 2 ft 6 i n by 1 1 ft 6 i n and 4 ft deep are

-
.
,
. . . . .
,

of 2 i n pi ne ( the older flat bo tto mtanks h ave 5 i n si des) and t h erefore

-
.
-
.

li gh t ; they are kep t ti gh t by rod hoops A tank stands i nsulated by glass plates -
.

on 3 wood en sup p or ts 4 by 1 0 i n and 2 ft 1 0 i n lo ng wh i ch are carr i ed by

,
. . .
,

cross beams Posts ti ed by braces 2 by 8 i n and 1 5 ft long carry steel

.
, ,
. .
,

U S Patent No
. . . 1 09 5 744 8 , May 1 5, 1 9 1 4 .
 DE S ILVE RI ZA TI ON OF LE AD B ULLI ON

r
t usses on wh i ch r e i
st nsu la t ed copp er b usb ar s by 1 0% i n ,
a nd 1 1 ft 2
. i n . .

lo ng A tank coated wi th pi tch fromoi l resi due i n the usual way hol ds 2 8
.
,
-

o c
an des and 2 9 at hod es T h.e anod es 2 4 by 36
,
i n and 1 % i n t
.h i ck we i gh
.
,

i ng appro xi mately 4 60 lb ar e susp e n ded fr om sho u l d er s ; th e c a t hod e s , 1 i n .

m
.
,

larger th an the anodes are suspe e e ch by 3

,
n d d a s tr i p s of l e ad fro c a thod e

.
lo
bars 2 ft 994 i n ng and . i n th i c
.k T h.e el e c troly t e wi,
th 1 0 p er c e n t P
. b
and 1 2 p er c ent H , S iF ° i s k ep t at 3 5 3
.
— 8
C c°
i r c.u l,
a ted i n t h e d i r ec ti o n of t h e
632 M E TALLURG Y OF LE AD

a rrows through a block of 4 tank s at a rate of 3 4 gal p er m i n by m eans of

— . .

hard r ubber p i pes Submerged copper centrifugal pum . ps wi th bronze sh af ts

raise i t to the head tank ; the troughs are of wood coated wi th pi tch T he .

c urr ent densi ty i s 1 7 1 8 am

—
p p er sq f t ; the fall i n po te n t i al p er va t i s . . .

0 50 vol t
. .

The B et ts dep artm ent of the refinery of the Am eri can Sm el ti ng and Refini ng

Co at Om . aha N eb confines i ts work to the treatm , ent of anod es w

.
,
i th abo ut
1 5 p er cent B i
. I t has 80 tanks i n seri es and 2 0 casca des or 4 tanks connected
. .
, ,

up accordi ng to the Walker system treated i n 1 9 1 7l

t ons le s d ,
.

Detai l s of tanks and electrodes are sh own i n Fi gs 700 70 2 Th e tank s are .

-
.

of asphalt concrete m ad e up of a m i xture asphal t asbes tos and sand ; the sp aces
, ,

between adjoi ni ng tanks are filled wi th concrete or crushed slag and p o ured
sulph ur The tanks r est on squar e glazed drai n pi pes ; these are supp or ted by
.
-

tw o courses of br i ck the upper of wedge and the lower of str ai gh t bri ck ; ,

between the co urses are placed sheets of copper wi t h troughs to carry off drai n
age The lower br i cks are sep arated by asphal t blocks
. Th e sup por ti ng bri cks .

are carr i ed by r ei nforced co ncrete beam s and t hese by co ncr et e pi ers T he , .

ends of a b lock are brac ed by woo den buck stays t i ed wi th M i n rods passi ng -
.

i n brass pi pes th rough the slag sulphur concr ete spac es ; the si des are rei nforced -

by 4 in walls buil t of wooden stri ps 2 i n thi ck and wooden posts anchored i n

-
. .
,

the concrete beam s A tank 1 0 ft i n long 2 6 i n wi de and 30 i n deep holds

.
, . .
,
. .
,

2 7 anodes and 2 8 cathodes The anode has bev eled si des ; i t i s 2 0% and .

2 1 2 in w i de 2 3% and . i n long 1 % i n thi ck and w

, ei ghs 350 lh ; th e .
,
.
,
.

cathode i s 1 i n wi der and longer than the anode i s . i n thi ck and w ei ghs ,
.
,

6 lb ; the fini sh ed catho de about 1 30 lb

. Th e tank wall s are covered wi th .

i nsulated oak p lanks 1 % X 6 i n whi ch carry pri m ary busbars , X 8 i n and .

, ,
.
,

secondary 1 MX 4 i n Anodes are exchanged through an overhead elec tri c

,
.

cr ane i n tank lo ts every 1 1 days ca thodes every 5 or 6 day

-
s ; the anode scrap ,

am —
o unts to 2 0 2 5 p er cent .

2 97 Corrosi on of Anode and Deposi ti on on Cath ode

.
— The corr osi on of
the anod e i s on the whole regular as the am ,
ount of i m p uri ty is co mpar ati vely , ,

sm all and prac ti cally all of i t i nsol ubl e I t has been fo und necessary to allo w .

from2 0 to 2 8 p er cent of the anode to remai n uncorroded whi ch goes as scra p .

,

to the anode k et tles The reason for thi s i s that i t i s necessary to provi de a
.

full unbroken anode surface for the mud to cli ng to Wi th the usual grade of .

lead b ulli o n onl y a small amo unt of mud is detached fromthe anode If the .

mud exceeds a certai n thi ckness i t gli des down fromthe anode or par t i cles
become detached and collect on the bo t tom Thi s i s li kely to cause shor t .

ci rcui ti ng as well as secondary ch em i cal r eac ti ons between the com ponents
of the mud and the free aci d of the elec trolyt e M ost plants clean up every .

1 0 or 1 1 d ays wh i ch coi nci d es wi th the r enewal of the anodes

, A tank load .
-

of corroded anodes wi th the mud adheri ng to mo st of them i s rai sed fromthe

, ,

vat and dep o si ted i n a tank car twi ce the si ze of the cell filled wi th wa ter
,
-

, , .

The anode m ud i s scraped 03 and the anodes are br ushed by hand or w i th ,

“
1
H of man , Cop p er, 1 91 8, 53 2 .
634 M E TALLURGY OF LE AD

Thu mrotary br u h hoi st to rai se and lower the anodes ; wh en

s es, usi ng an elec tri c
clean they are raised ri nsed and transferred to the anode k ettles The mud
, , , .

i s p ar tly set tled p um p ed wi th r emai ni ng elec, t roly te t hro u gh a fi l t er pr ess ,

washed wi th water dri ed wi th ai r or o ther means and di scharged when rea dy

, ,

for f ur th er treatm ent A bronze ( Cu 9 5 Sn 5) Johnson or Schri ver pr ess

.
, ,

1 8x 1 8 i n w i th 1 2 l eav es furni sh es 1 i n c ak es w
. h i ch retai n 30 p er ,
-
.
,

cent water and wei gh 400 500 lb The elec trolyte i n the por es of the sli me
.
— .

tak es up som e l ead w hi ch i s not removed by the wash water The first ( strong ) -
.

filtrate consi sti ng of elec troly te goes to the h ead tank ; the di lute w ea k
, ,

por ti on i s used for first water i n the anode wash tanks M o st of the so luble -
.

lead i s removed by fil teri ng but the mud r etai ns about 1 0 p er cent ,

.

i nsol uble lead .

The ca thod e deposi t under good worki ng condi ti ons i s sm oo th but oth erwi se ,

ro ugh and streaked ; at the edges i t i s thi cker than at the center ; and freq uentl y
knobs are formed The ca thodes are also removed by tankloads to a washi ng
.

tank spr ayed wi th water and tr ansferr ed on a car to the m

, el ti ng k et tl es
, .

D i l ute sol uti ons are evaporated .

2 98 Anode M ud .
—
T he anode m ud ob tai ned from th e corroded anod es
.

and coll ec ted fromth e tank s v ari es i n co m posi t i on as seen i n Table 1 52 .

TAB LE 1 52 — C01t p 0s1r1 0N or AN ODE

. MUD

More com p l e te an a ly s e s h a v e b ee n p u b li sh ed by B e t t s W h i te h ea d an d K er n ,
l
,
z ’

The tr eatm
.

ent of the m ud i s gov er ned by th e p resence or absence of B i

and wi th i t of Te and Se; i t i s co m par ati vely si m p l e if B i T e an d S e a re a b s e n t ; , ,

i t i s com p li c a ted if B i i s t o b e r ecov e r ed .

Whatever may be the trea tment the mud com i ng from a filter pres s or ,
-

suc ti on fil t er i s so m ewhat ai r dr i ed tr ansf err ed to i ron trays on i ron ca rs -

, ,

wheeled i nto the flue of the reverberatory smelti ng f urnace or i nto a connec ted ,

drying chamb er and allowed to r emai n there for from2 4 to 4 8 ho urs that t h e
,

moi sture may be dri ven 03 and the metals more or less oxi diz ed .

The anode m ud fromTr ai l B C i s fr ee fromBi and Te The ox i d i z ed

,
. .
, .

mud i s mel ted i n the coal fired reverberatory furnace shown i n Fi gs 703 -
.

7 50 , th e h e a r th of wh i ch i s l i ne d w i th m agn esi te br i ck F ro m 2 0 t o 2
5 t o n s of .

par tly oxi di zed mud are smel ted i n abo ut 1 0 days wi tho ut the use of any flux th e ,

anti m ony slag bei ng rak ed off as soon as the hear th i s filled Wh en toward t h e .

Tr A I . . M E 1 904 xxx i v 1 8 2 1 83
. . .
, , , , .

‘
M i nes and Mi nerals 1 905 xxv 2 88 , , , .

‘
M et ChemE ng , . . . 1 91 1 , ix, 41 7 .
 DE S ILVE RI ZA TI ON OF LE AD B ULLI ON 635

end of campai gn the last of the anti mony slag has been r emoved there ri ses
a , ,

to the surface of th e doré si lv er a cr ust consi sti ng mai nly of CuzO ; thi s i s sk i m

med and the doré silver from

, , to o
z di pp ed T h e anti m
.
, o ny
.

s lag ,
wh i ch a ss a y s fro m 3 00 t o 500 oz .doré p er to n i s
,
r e sm el te d o n c e or t w i c e

wi t h fine co al i n th e r ev erb er atory f ur nac e wh ,

er eby i ts co n t en t i n pr ec i o u s

meta i s e
l r d u c ed to a bo u t 8 o z .Agp e r to n .T he p u r i fi e d an ti m o n y slag t h e n

goes to the blast furnace to be sm el ted for hard lead .

636 ME TALLURGY OF LEAD

In 1 908 A I . M cN a
.b work e d o u t a t l
T ra il B C a w e t pro ce s s fo r th e ,
. .
,

treatm ent of th e anode m ud whi ch consi sted of the followi ng step s :

,

( )
1 Sol u ti o n of Sb A s
T e an d , S e i n
, sod i u m poly, s u lp hi d e a n d el e c tr o d e p o s i -

ti on of anti m onyfro mthe fil tered soluti on; accum ulati ng arseni c i s to be t e

moved by concentrati on of li quor to 35 R6 and subseq uent cooling ( 2 ) °
. .

Sulphati zi ng r oast of the resi due (Ag Pb Bi Cu Au) ; ex trac ti on of c0pp er , , , ,

( also so m e A g a n d B i ) w i th w a te r a n d s u lph u r i c a c i d ; pr e c i p i ta t i o n of s il v e r
and bi sm uth wi th copper (3) F u si on
. of th e r e si d u e ( A u A g P b B i ) fro m le a c h , , ,

i ng the sulph ati zed m ateri al i n a r everber atory f ur nace ; separati o n of lea d and
,

bismuth from gold and si lver by cupellati on; recovery of bismuth by the
known methods ; concentrati on of th e copper soluti on etc ,
.

The process w as p ut i nto operati o n but gi ven up agai n wh en the Sb i n , ,

the har d l ead bro ugh t the sam e pr i ce as i f unalloy ed wi th l ead .

The treatm ent of anod e m ud contai ni ng Bi has been work ed out at th e

works of the U S M etals Refini ng Co E ast Chi cago Ind and i s used i n a
. . .
, ,
.
,

modi fied format Omaha Neb ,

.

Detai ls are r eserved for the present ; they will be di scussed in a later work
i n co nnec ti on wi th the m etallurgy of bi sm uth .

2 99 Com .
p a r i so n B e tts a nd P a rk e s P r oc e ss e s — I t h a s be e n s ta t e d th a t
there exi st only fo ur plants whi ch use the Betts and that i n one of these i t ,

forms a subordi nate depar tment for the treatm ent of lead bulli on r i ch in Bi .

The advantages of the Betts process are that i t f urni sh es a hi gh yi eld of refined
lead that i s free fromBi and a means of recover i ng thi s metal The disadvan
,
.

tag es are that the refined l ead co ntai ns 0 2 0 to oz Ag p er ton versus . to .

oz of the Park es lead and that th e co st of el ec trolysi s i s 50 p er cent m

.
,
ore than .

that of zi nc desi lveri zati o n In order that the Betts process m

. ay com pete
wi th the Parkes i t i s essenti al that the Bi co ntent of the lead b ulli on at least
,
-

make good the di fierence i n cost of treatment The Bi content of the usual run .
-

of lead b ulli on i s very low I t i s the common prac ti ce of Parkes plants to sacri
.

fice the Bi and to m ak e up sof teni ng f ur nace ch arges wh i ch contai n l ess th an -

p e r c en t B
. i a nd th,
u s prod uc e a r e fi ne d l ea d wh i ch m ee t s t h e r e q u i r e m e n ts

of corr odi ng lead .

1
U S Patent No 907754, Dec
. . . . 1 ,
1 908 .
638 ME TALLURGY OF LE AD

o
n se, c d upon by gastri c j ui ces and the di ssolved lead form
is a te s the poi s o n , .

The solvents i n gastri c j ui ce are hy drochlori c aci d and pep tone .

3 0 1 L e ad
. an d i t s Co m p o u n d s a s P oi so n s — T h e bo i l i ng po i nt of m e ta l li c -

lead i s 1 52 5 C but the metal i s volati le at much lower temperatures T he

°
.

experi m ents of Lew i n have shown that at atm osph eri c pressur e m olten lead
l

does not gi ve ofl any vapor at from500 to 52 0 C that at 850 to 900 C ° °

.
,
°
.

so m e i s no ti c eabl e, and th at the pr esenc e of o th er m etals espec i ally zi nc and ,

anti m ony causes vapor to format 750 to 800 C Lead vapor i s qui ckly
,
° °
.

changed to oxi de .

Lead sulph i de m
° ° °
el ts at 1 1 2 0 C but i s vol ati le at 600 to 800 C ; i t i s .
, .

°
oxi di zed at 360 to 380 C i nto oxi de and sulphate
°
. .

°
Load oxi de i s volati le at 883 C .

°
Lead sulph ate i s spli t at 900 C i nt o basi c sul ph ate and sulp hur t r i oxi de . .

°
Load carbonate i s di ssoc i ated at 3 1 5 C i nto l ead o xi de and carbo n di oxi de . .

Metalli c lead i s spari ngly sol uble in hydrochlori c aci d Of the di fferent .

com pounds lead sulphi de i s least soluble at body tem

,
perature i n gastr i c j ui ce;
then follows lead sulph ate norm al and basi c ; the oxi de bo th norm
, al and bas i c ,

carbonates are the m ,

ost soluble .

The lead in the d ust and f um e of sm el teri es i s not an ac ute poi s on I ts .

efl ect i s c um ula ti ve; sm all quanti ti es taken i nto the body by dai ly co nt ac t wi t h

th e source are ab sorbed by the system Th ey sh ow th ei r e