The sintered cakes are finally discharged automatically into cars. Details regarding the machine vary at different smelters; at one works the length is 30 feet, the rate of travel 8 inches per minute, and the vacuum in the suction chamber 6 ozs.
The size of the particles should not exceed ¼ inch, and not more than 25 per cent. of the charge should be so large. Some 3 to 5 per cent. tends to pass through the grids, and so be drawn into the suction chamber; this is cleared out at intervals through special doors. Water is necessary, and from 6 to 10 per cent. must be employed in uniformly moistening the charge, which, by the addition of suitable fluxes, is often made of such proportions that in subsequent blast-furnace smelting a satisfactory slag is produced without further additions. The sulphur reduction by the process is very considerable.
Fig. 16.—Dwight-Lloyd Sintering Machine.
Such blast-roasting methods, with suitable modifications, promise to assume considerable importance in the developments of modern smelting practice.
c. Roasting.—Roasting is often a very important preliminary stage in the scheme of treatment of copper ores. It was formerly considered an essential operation in smelting processes for sulphide ores, the material being crushed and concentrated largely with a view to such subsequent treatment. This is not the practice in modern smelting. Roasting is now only conducted where the necessity for it arises, as in the case where wet dressing, having been considered advisable, has resulted in the production of large amounts of fine concentrate, and where reverberatory furnaces are installed for the smelting of this material. Preliminary roasting of the concentrates then conduces to the production of a matte of converter grade in one smelting operation.
The Principles of Copper Smelting.—Copper extraction from sulphide ores is essentially an oxidation process, the iron and sulphur being oxidised and the oxide of iron slagged away. All such smelting processes, both the older and the more modern ones, are based on this fact, and underlying all of them are certain fundamental principles which it is essential to keep in mind in considering every phase of the subject.
These may be summarised as follows:—
(1) In the melting down of a furnace charge, the copper has first claim on any sulphur which may be present.