The draft record is placed close to the charging platform, in order to be in a convenient position for the guidance of the workmen. The draft in the main flues is 1·7 to 1·8 inches water pressure; this is similarly recorded in the foreman’s office.
7. Continuous Working of the Furnace.—The continuous working of the furnace is a most important factor in modern practice, and is naturally inseparably bound up with the principle of maintaining the heated matte-pool in the furnace, which allows of the continuous charging of hot “calcines,” and the continuous or regular withdrawal of slag and of matte when required.
Fig. 24.—Draft Pressure Record of Anaconda
Reverberatory Furnace (Offerhaus).
The matte (which can be efficiently settled, owing to the prevailing high temperature and the large mass of heated material in the furnace) is stored there until required at the converters, when the desired quantities are tapped out. The slag which is produced by the smelting action gradually accumulates, and at regular intervals most of it is run out (rather than skimmed). This usually takes place every four hours. The slag accumulates until it reaches a level some 3 or 4 inches above the skimming plate at the end of the furnace, and the quantity which is run out at each “skimming” amounts to some 60 or 80 tons, the contents of the furnace being lowered to such an extent that a fresh accumulation of material may proceed during the next four hours. No pulling of the slag is required as in the older methods of working, since the material is so very hot and fluid that it simply pours out of the furnace, and twenty minutes usually suffices for the whole of the 60 or 80 tons to run off, the rabble being used chiefly to regulate and control the stream, and to keep back siliceous crusts or floaters. The slag is run out until the matte is seen underneath, on flapping back a thin layer, or until the level of the skimming plate is reached, and its removal is such a short and simple operation that there is very little interference with the regular and continuous running of the furnace. Similarly, the tapping of as much as 50 to 100 tons of matte from the store of 250 tons of hot fluid material has little influence on the continuous working. Charging of coal and calcines is performed at regular intervals, and the charges of 15 tons of “calcines” fed in at a time, readily melt down and settle. Practically the only interference with continuous running is the necessity for claying and repairing, and the use of the matte pool on the hearth has lessened the frequency for this to a large extent, the hearth bottom itself being protected from corrosion, owing to the sulphides exerting no action upon it, whilst the oxides in the charge which would be capable of attacking the siliceous bottom are slagged off before they get an opportunity of reaching it. The hearth bottom, if properly put in, is practically permanent.
The portion of the furnace most subject to corrosion is at the slag line, where deep channels are gradually cut out. Every four to six weeks the furnace is tapped dry, repaired, and fettled, as much as 20 tons of fettling sand being often required for this purpose. The sand is thrown in and patted into place by long rabbles, the operations occupying about eighteen hours. Every nine months or so the furnace is repaired more fully, 20 or 30 feet of brickwork near the fire-bridge being taken down, and the great cavities in the side walls repaired by masons, using silica bricks. The employment of higher temperatures in modern work allows of more siliceous slags being produced, which lessens the tendency to the eating away of the walls.
The feeding of siliceous copper ores through a series of small hoppers situated in the roof, near to the walls, has lately been introduced with a view to protecting the furnace sides from the corrosive action of the slag, and to exposing a suitable siliceous flux to this material. This appears to have fulfilled its purpose to some extent, but various difficulties have been encountered in practice, especially the tendency for the cold added material to form floaters, which require limestone additions in order that they may be fluxed off; and the cooling effects and leakages through the openings have also given trouble.
8. Modified Constructional Details.—In addition to the increased size of fire-box, hearth, and flues, and to the necessity for very heavy staying in order to keep the enormous arch in permanent shape, which are characteristic of modern practice, the construction of modern furnaces involves the building of a suitable hearth to carry the heavy burden of hot and fluid matte which is stored in the furnace.
It was formerly considered correct practice, in the smaller types of furnace, to construct the hearth over a vault, in order to keep the underside cool and thus prevent the corrosion and eating away of the siliceous bottom by the oxidised charges, during the process of melting down. In modern practice it is absolutely essential to work with a perfectly solid structure.