Fig. 53.—Details of Slag Spout, Cananea.
Fig. 54.—Slag Spout, showing Method of Support.
The position of the outlets from the furnace, connecting to the settlers, is largely affected by the available floor space and the general lay-out and arrangements of the plant. Under suitable conditions, and especially with long furnaces, the arrangement of the settler in front of the furnace works very advantageously, leaving the alignment of the blast furnaces free, and allowing plenty room for working around the settlers. The settlers are then arranged in the middle line of the crucible portion of the furnace, so that working is conducted evenly from both ends of the furnace towards the discharge in the centre, and the smelting is thus regular and allows of good control. At many smelters the discharge of products takes place from spouts at the ends of the furnaces, the settlers thus being in alignment with them. This plan, under suitable conditions, has several advantages, permitting of ready access to the sides of the furnace, even working of the furnace by discharge at both ends, and ready co-operation between adjoining furnaces and settlers.
Settlers.—The modern type of settler is often circular in section, about 16 to 18 feet in diameter and 5 feet in height, storing about 40 tons of matte. Other forms, rectangular or oval, are, however, also employed.
The outer shell is of ½-inch steel plate bound together by band-bolts, the lining is often 9 to 15 inches in thickness, with an inside layer of looser stuff. The lining material employed varies greatly, according to the grade of matte, character of slag, and working conditions. The wearing out of the lining depends very largely on the class of material passing through the settler, the most rapid wear being occasioned by the fiery and corrosive low-grade mattes and basic slags, whilst high-grade mattes and more siliceous slags give little trouble in this connection. The more corrosive the products, the more refractory and hard-wearing must be the lining, and consequently the materials employed for the purpose range from chromite, silica brick and firebrick down to loam, according to the requirements; the chief duty is that of being non-corrodible and of protecting the outer shell. It is not an uncommon practice to thicken the walls close to the tap-holes, where they are subjected to most wear, and often chromite is used at these points owing to its power of withstanding the forces of erosion. On the other hand, at the Copperhill Smelter of the Tennessee Copper Company the settlers have been found to give as satisfactory service on fairly low-tenor matte, when lined throughout with good firebrick as with the more expensive materials formerly used, whilst still more recently, siliceous copper ores have been successfully employed as lining material instead of bricks.