2PbS + 2O = SO2 + Pb + PbS.
Thus one-half of the lead is reduced, and it is found collects all the silver of the ore; the other half is sublimed as lead sulphide, which is free from silver. The reaction is exothermic to the extent that the burning of one-half the sulphur of a charge should theoretically develop sufficient heat to volatilize half of the charge and smelt the other half. This is almost done in practice with very rich galena, but not so with poorer ore. The temperature of the furnace must be maintained at about 1100 deg. C. throughout the whole operation, and there are the usual losses of heat by radiation, absorption by the nitrogen of the air, etc. Deficiencies in heat are supplied by burning some of the ore to white lead, which is mixed with the black fume (PbS) and by the well-known reactions reduced to metal with evolution of sulphur dioxide. The final result is therefore the production of (1) pig lead enriched in silver; (2) pig lead free from silver; (3) a leady slag; and (4) sulphur dioxide. In the case of ores containing less than 75 per cent. Pb the gangue forms first a little skin and then a thick hard crust which soon interferes with the operation, especially if the ore be zinkiferous. This difficulty is overcome by increasing the temperature or by fluxing the ore so as to produce a fusible slag. A leady slag is always easily produced; this is the only by-product of the process. The theoretical reaction requires 600 cu. m. of air, assuming a delivery of 50 per cent. from the blower, and at one atmosphere pressure involves the expenditure of 18 h.p. per 1000 kg. of galena per hour.
Fig. 26.—Plan and Elevation of Smelting Plant at Clichy.
The arrangement of the plant at Clichy is shown diagrammatically in Fig. 26. There is a round shaft furnace, 0.54 meter in diameter and 4.5 meters high. Power is supplied to the blower C through the pulley G and the shaft DD. The compressed air is accumulated in the reservoir R, whence it is conducted by the pipe to the tuyere which is suspended inside of the furnace by means of a chain, whereby it can be raised or lowered. O1 and O2 are tap-holes. L is a door and N an observation tube. A is the charge tube. X is the pipe which conveys the gas and fume to the condensation chambers. T is the pipe through which the waste gases are drawn. V is the exhauster and S is the chimney. K1 and K2 are tilting crucible furnaces for melting lead and galena.
After the furnace has been properly heated, 100 kg. of lead melted in K1 are poured in through the cast-iron pipe P, and after that about 200 kg. of pure, thoroughly melted galena from K2. Ore containing 70 to 80 per cent. Pb must be used for this purpose. The blast of air is then introduced into the molten galena, and from 1000 to 3000 kg. of ore is gradually charged in through the tube A. During this operation black fume (PbS) collects in the condensation chamber. All outlets are closed against the external air. If the air blast is properly adjusted, nothing but black fume is produced; if it begins to become light colored, charging is discontinued and the blast of air is shut off. Lead is then tapped through O2, which is about 0.2 meter above the hearth, so there is always a bath of lead in the bottom of the furnace; but it is advisable now and then to tap off some through O1, so as gradually to heat up the bottom of the furnace. Hearth accretions are also removed through O1. The lead is tapped off through O2 until matte appears. The tap hole is then closed, the tuyere is lowered and the blast is turned into the lead in order to oxidize it and completely desulphurize the sulphur combinations, which is quickly done. The oxide of lead is scorified as a very fusible slag, which is tapped off through O2, and more ore is then charged in upon the lead bath and the cycle of operations is begun again.