Fig. 65.—Basic-Lined Converter, indicating Tuyeres, Lining, etc.
Converter Linings.—The question of the lining has been the most important consideration in copper matte converting-practice.
The functions proper of the lining material are—
- (1) To preserve the steel shell and form a permanent receptacle for the molten materials; by reason of its refractory character.
- (2) To prevent undue losses of heat from the materials; by reason of its low conducting power.
The employment of the lining material as a provider of suitable siliceous flux for the iron oxide, though until recently of vital importance for the practical operation of the bessemerising process, has been a necessary evil in many cases, and although it might have been a source of considerable profit under certain conditions, this function is unlikely in the future to be the consideration of greatest moment.
The vital requirements in modern converter practice are permanence of the lining and efficient means of effecting the fluxing of the iron oxide produced in the converting operation. The necessity for the frequent relining of converters involves not only heavy direct expenses, but it occasions waste of heat in the old linings, waste of material, loss of time, interruption of the processes, liabilities to outbreaks from the converters, and necessitates much heavy machinery for the conveying of vessels for relining, as well as large capital outlay in relining shops, plant, and appliances. In consequence, the employment of siliceous lining material as flux is usually a most expensive method of supplying the requisite silica; and so much is this the case, that an arbitrary limit to the iron contents of the matte has been rendered necessary, in order to prevent too much of the lining material being used up at a single blow. It was found cheaper to use other means of concentrating low-grade matte to a suitable grade for bessemerising—i.e., to flux off the excess of iron by means of silica in the blast-or the reverberatory-furnace processes.
Siliceous Linings.—Until recently, the only method for fluxing the iron in bessemerising, found practicable on a commercial scale, has been by the destruction of the siliceous lining, minimising the dead losses as much as possible by employing for the purpose siliceous materials from which values in the form of gold, silver, or copper could be simultaneously extracted and collected in the products of the operation.
Numerous attempts were made to effect combination of the iron oxides with silica introduced by some other method, but none met with success. Manhès blew sand through the tuyeres, and obtained as result a spongy unfused mass in the converter—whilst silica introduced in the form of lumps rose to the surface unchanged. In each case what silica was required for flux, was taken up from the siliceous lining. Experiments of a similar nature, in which basic linings were worked with, resulted in the fluxing silica being unabsorbed as before, whilst the iron which was in process of oxidation, not finding a suitable flux, became super-oxidised, resulting in the production of very infusible masses of magnetic or ferric oxides which rendered the process unworkable. Baggaley and others in Montana devoted much attention to experiments on different methods for introducing silica which would flux successfully, methods such as superheating or introducing silica held in suspension in fused silicates being tried, but without marked success, and for many years siliceous linings were necessarily worked with.