(a) For the successful operation of acid-making plant, as at present developed, it is necessary that the proportions of sulphur dioxide in the gases shall not fall below a certain minimum, and further, that the gases shall not contain more than certain limiting proportions of other interfering constituents, such as, for instance, CO2. It is for this reason that the blast furnace operating the true pyritic process furnishes gases of the type most suitable for acid manufacture, since by this process the sulphur-dioxide is obtained in the gases in the most concentrated and the least contaminated form possible under smelting conditions. Even under these circumstances the gases are not in the least of an ideal composition for treatment, owing to their dilution with nitrogen, etc., and the development of the acid-making plants and processes adopted for the successful utilisation of copper blast-furnace gases furnishes a record covering many years of very slow and costly experiment, marked by many preliminary failures and disappointments. These difficulties have now been overcome, as the working of the successful plants attached to both of the Tennessee copper smelters affords conclusive proof, and the sulphur which formerly cost money to dissipate by roasting, now not only acts as fuel, but furnishes a very profitable bye-product.

The requirements for the gases are chiefly the presence of sufficient SO2 and oxygen, and of as little CO2 as possible—factors which depend largely on the proportions of sulphide in the charge. The gas for the acid plant must be supplied in regular and continuous amount, at a specific temperature, and this calls for special care in the smelting operation, furnace manipulation and blast supply, supplementary air admission, etc.

About 3·5 to 4 per cent. of SO2 in the gases delivered at the chambers is the minimum proportion for satisfactory working; CO2 should not exceed about 5 per cent., and about 6·0 per cent. or more of oxygen is also necessary.

(b) In addition to the capital charges involved in the acid-making installation and the costs of adapting the furnace plant and operations to the process, the problem of putting the acid upon the market on a satisfactory economic basis is important, particularly in view of the competition from other sources. The districts which offer a consuming area for the large and regular supply of acid from the smelters are not unlimited in number, and are probably readily accessible to other sources. In view of the costs of production, the distance of the smelter from the market is a serious consideration, since freight charges on sulphuric acid are high, involving special regulations with respect to the form of car and conditions of traffic, and they may readily exceed all possible profits resulting from the sale of the product.

In Tennessee the companies were forced to install acid plants. That at Copperhill is the largest in the world; commenced in 1906, acid manufacture began about two years later, after much experimenting, and further units have gradually been added. The plant now includes two Glover towers, 30 feet across and 50 feet high, 64 cooling chambers about 11 feet × 11 feet × 70 feet high, eight cooling chambers 11 feet × 24 feet × 70 feet high, twelve old chambers 50 feet × 50 feet × 70 feet, six new chambers 50 feet × 50 feet × 75 feet, eight new chambers 23 feet × 50 feet × 80 feet, eight Gay-Lussac towers, with complementary tanks, etc.—producing at the rate of 168,000 tons of 60° B. acid per annum.

The Ducktown Company’s plant was installed in record time, and, like the Copperhill plant, comprises elaborate dust chambers and flues, with Glover and Gay-Lussac towers of special design and construction, and enormous acid-making chambers with complex valves and fittings. The plant is designed to produce about 160 tons of 60° B. acid daily. The analysis of the gases supplied to the towers varied during the early working of the plant; under fairly normal conditions the average analysis of the gases delivered is SO2 3·5 per cent., CO2 3·5 per cent., SO3 trace; the oxygen in the mixture being about 8·0 per cent. The temperature is also apt to vary. Full details on these points are not yet available for general service.

The management of both companies have been successful in obtaining particularly satisfactory contracts for the purchase of their acid by fertiliser corporations.

References.

Peters, E. D., “Principles” and “Practice of Copper Smelting.”