In spite of the difficulties connected with the process, as detailed above, the method has proved itself an exceedingly profitable one on a large scale, and the experience of the companies financially interested, as well as the opinions of managers of the plants in practical operation, leave no doubt as to the economic success of this application of scientific principles to a practical problem on a very extended scale.
Special Features of Pyritic Smelting.— Several points of particular interest have given rise to much discussion in connection with pyritic smelting practice. These include the question of the coke proportion required on the charge, and the advisability or otherwise of employing heated blast for the furnace.
Coke Proportion.—Whilst ideal pyritic practice involves the entire absence of supplementary carbonaceous fuel, it has not been found practicable, up to the present, to ensure satisfactory working over any reasonable period of time, unless a minimum of about 1·25 per cent. of coke is incorporated with the charge. The function of this coke has been a matter of much speculation, but the investigations of Sticht already referred to, now permit the tracing, with some considerable accuracy, of its function and of its action in the furnace.
It is found that in true pyritic smelting the coke does not reach the bessemerising zone at all, but that it is completely consumed in the regions above this point. It is, moreover, not burned by the oxygen of the air, none of which exists above the tuyere zone, since all this oxygen is consumed by the combustion of the sulphide. It appears that the coke is oxidised by the SO2 which results from this sulphide combustion. The examination and analysis of samples of the gases withdrawn from different parts of the furnace have confirmed this view, and have elucidated the probable reason for the apparent necessity of a certain small proportion of coke in the process, under the present conditions of working. The heat generated from the oxidation of the coke by the SO2 is of much value in preheating the materials of the charge for the removal of excess sulphur and the liquation of the sulphides. The amount of heat which is available for this operation is small, being practically all derived from that carried upwards by the hot gases leaving the smelting zone, and none is obtainable by the usual processes of coke or sulphide oxidation in the upper regions of the furnace, since no available oxygen is believed to get past the bessemerising zone and reach these upper areas. It is indeed necessary for the success of pyritic smelting that such oxidation or roasting of sulphides in the upper part of the furnace should be prevented, since every available particle of iron sulphide is required for heat production at the smelting zone, by its combustion there, and any oxidation elsewhere not only deprives this zone of fuel, but spreads the heat over too wide an area for sufficiently intense combustion.
Thus, by supplying an additional amount of heat to the upper parts of the furnace, where heat is needed to assist in the preparation and liquation of the sulphides, the extra coke, in being oxidised by the SO2 without robbing the tuyere zone of fuel or air, just fulfils its useful purpose at the required place, in such a way as to keep the smelting operation running smoothly.
The presence of more coke than is absolutely necessary for the fulfilment of this purpose is, in addition to its extra cost, of no advantage, and in true pyritic smelting none should reach the tuyere zone, since it introduces a reducing influence where the most marked oxidising effect is required. By consuming oxygen for its combustion, it deprives the iron sulphide of this material, less iron is, therefore, oxidised, and the matte is consequently increased in quantity and lowered in grade, whilst the amount of iron carried into the slag is decreased.
1·25 per cent. of coke is about the minimum quantity with which it is found practicable to maintain satisfactory working of the furnace under present conditions, 0·5 per cent. has been worked with occasionally, and none at all over certain short periods of time. The average quantity employed is from 2 to 3 per cent., and when about 5 per cent. is used, coke reaches the tuyere zone and the process ceases to be truly pyritic—the reactions and smelting conditions become entirely changed.
It does not seem unlikely that, as knowledge of these conditions increases and as the mechanism of the process becomes more generally understood, modifications in furnace design and blast conditions may lead to the successful operating of the pyritic process entirely independent of the use of coke fuel.
Heating of the Blast.—For true pyritic smelting it has been shown in practice that the use of heated blast possesses no advantages; many smelters operating the process have tested the effects, and have usually given the method up, whilst the work of Sticht and Peters affords valuable evidence and close argument as to the reasons for its unsuitability. Success in true pyritic working depends upon the intensity of oxidation of the sulphides, and upon the localisation of the resulting heat at the narrow bessemerising zone situated just above the tuyeres. The greater the quantity of iron which is there oxidised per minute, the better is the concentration, the greater is the smelting and fluxing intensity and the higher is the resulting temperature. Since the character and composition of the slag vary in accordance with these conditions, depending largely upon the temperature in the tuyere zone, the furnace works most rapidly and satisfactorily when slags of high formation temperature are being produced. These can only be formed if much iron is being oxidised, because iron is the chief fuel in the process. The addition of extra heat by warming the blast appears to allow of the formation of silicate slags possessing a lower formation temperature, such slags are less basic, and consequently less iron need be oxidised and slagged off per minute in order to produce them. Less iron sulphide fuel is, therefore, burned, and the reaction intensity at the tuyere zone is reduced, so that the necessary heat margin for satisfactory smelting may not be attained. The extra heat carried in by the warmed blast may not be sufficient to compensate for that which is lost owing to this decrease in oxidation intensity; the furnace consequently tends to work cold, whilst the excess air supply leads to the production of over-fire, by the oxidising of sulphides higher up in the charge.
These features are specially interesting, as they afford one of the most marked distinctions between true and partial pyritic smelting. In the latter process, the fuel value in the adjustable supply of coke at the tuyeres allows of the ready production of any extra heat which might be required. The slag composition is, in consequence, more independent of the furnace conditions, since the heat required for the smelting operation does not depend so much on the formation of slag of any particular composition. Sufficient heat is always obtainable by coke additions when smelting for any special slag which may be desired. Neither is localisation of the heat at the narrow tuyere zone so essential in partial pyritic smelting. Warm blast produces a greater combustion intensity when employed in oxidising carbon, so that it may present advantages, both economic and operative, in partial pyritic work, whereas it is distinctly disadvantageous in the true pyritic method.