The maximum and best average size under ordinary conditions is 40 feet by 24 feet, by 7 feet high above the bed of fuel. The height is important, and varies with the quantity of sulphur in the ore. The lower the sulphur content, the higher the pile; with about 40 per cent. sulphur, the best height is 6 to 7 feet; with 15 per cent. of sulphur, up to 9 feet; and if still less sulphur be present, the height may even be a little greater. Such a heap holds about 240 tons, and if the quantity of ore to be dealt with exceeds this, a number of such piles should be constructed. The time occupied in roasting is about 70 days, with 10 days more for removing and rebuilding.
The selection of a proper site is important.
(a) The prevailing direction of the wind must be considered, so as to keep the fumes away from the works and offices.
(b) The yards must be protected from winds, so as to prevent losses of dust, as well as uneven burning.
(c) The ground must be perfectly dry or drained.
Along the upper edges of the roast-yard a deep trench should be cut, so as to catch rain-water, and prevent it from washing soluble copper salts out of the pile; drainage trenches must also be provided to carry any copper-bearing liquors to some point where the copper can conveniently be precipitated on scrap iron. Enormous losses of copper may occur if these precautions are not observed; thus, at one period in the old roasting process in Tennessee, as much as 34 per cent. of the copper in the heaps was lost in 186 days.
Preparing of the Floor.—Remove roots and subsoil, fill space with broken stone or rough tailings, cover with 4 to 6 inches of clayey loam, and beat down well. The floor is then fairly impervious, and does not crack on drying. The ground should be given a gentle slope so as to facilitate draining. A layer (about 6 inches thick) of fine ore is next put down, then 9 inches of fuel; channels are now mapped out by means of logs set in both directions, leading to rough chimneys. The pile is then constructed, with the lower parts of the very coarse materials, smaller stuff being put towards the top and sides. On the very top and at the outside of the pile are placed the fines, but this top cover is only put on when the burning is well started. This process is still worked at Tyee, B.C., and at some other localities, but is most probably only a temporary plan, to be replaced by a more efficient method as development progresses.
B. Kilns for Lump Ores.—Kilns possess the advantage that they permit of arrangements being made for the recovery of SO2 for acid manufacture, and the subject belongs more properly to that branch of technology. Few large smelting works employ kilns for roasting lump ores, though there are important exceptions at works both in Britain and on the Continent of Europe. Kilns are used at the Cape Copper Company’s smelter at Britton Ferry, for this purpose.
(b) The Roasting of Fines.—Fines (and particularly fine concentrates) are the usual materials subjected to roasting. The finer the particles, the more rapid and complete is the oxidation, but the losses by dust are heavier. The size limit is thus liable to some variation, but often the material roasted is that under ⅜-inch in size.
Roasting Furnaces—Requirements.—For the roasting of fines there is simply required a place where the material can be gently heated in the presence of a constantly renewed air supply. The fuel has itself a reducing action, it must therefore be separated from the charge, and hence the furnace employed is of the reverberatory type. Muffles are never used for the oxidising roasting of copper ores. Since only a moderate temperature is necessary for the operation, the furnace needs but a small fireplace, and it is provided with a large hearth area. The fuel used is one yielding the fairly long oxidising flame required.