BLOWERS AND BLOWING ENGINES FOR LEAD AND COPPER SMELTING
By Hiram W. Hixon
(July 20, 1901)
In the Engineering and Mining Journal for July 6th I note the discussion over the relative merits of blowers and blowing engines for lead and copper smelting, and wish to state that, irrespective of the work to be done, the blast pressure will depend entirely on the charge burden in any kind of blast-furnace work, and that the charge burden governs the reducing action of the furnace altogether. Along these lines the iron industry has raised the charge burden up to 100 ft. to secure the full benefit of the reducing action of the carbon monoxide on the ore.
In direct opposition to this we have what is known as pyritic smelting, wherein the charge burden governs the grade of the matte produced to such an extent that if a charge run with 4 to 6 ft. of burden above the tuyeres, producing 40 per cent. matte, is changed to a charge burden of 10 or 12 ft., the grade of the matte will decrease from 40 per cent. to probably less than 20 per cent. I can state this as a fact from recent experience in operating a blast furnace on heap-roasted ores under the conditions named, with the result as above stated.
I was exceedingly skeptical about pyritic smelting as advocated by some of your correspondents, and still continue to be so; but on making inquiries from some of my co-workers in this line, Mr. Sticht of Tasmania, and Mr. Nutting of Bingham, Utah, I have arrived at the following conclusion, to which some may take exception: That pyritic smelting without fuel, or with less than 5 per cent., with hot blast, is practically impossible; that smelting raw ore with a low charge burden to avoid the reducing action of the carbon monoxide, thereby securing oxidation of the iron and sulphur, is possible and practicable, under favorable conditions; and that a large portion of the sulphur is burned off, and the iron, without reducing action, goes into the slag in combination with silica. These results can be obtained with cold blast.
A blowing engine would certainly be much out of place for operating copper-matting furnaces run with the evident intention of oxidizing sulphur and iron and securing as high a grade of matte as possible, for the reason that to do this it is necessary to run a low charge burden, and with a low charge burden a high pressure of blast cannot be maintained. With a 4 to 6 ft. charge burden the blast pressure at Victoria Mines at present is 3 oz., produced by a No. 6 Green blower run at 120 r.p.m.; and a blowing engine, delivering the same amount of air, would certainly not give more pressure. Under the conditions which we have, a fan would be more effective than a pressure blower, and a blowing engine entirely out of the question as far as economy is concerned.
I installed blowing engines at the East Helena for lead smelting where the charge burden was 21 ft. and the blast pressure at times went up as high as 48 oz. Under these conditions the blowing engines gave satisfaction, but I am of the opinion that the same amount of blast could have been obtained under that pressure with less horse-power by the best type of rotary blower. I do not believe that the field of the blowing engine properly exists below 5 lb., and if this pressure cannot be obtained by charge-burden conditions, their installation is a mistake.
I wish to add the very evident fact that varying the grade of the matte by feeding the furnace at different hights varies the slag composition as to its silica and iron contents and makes the feeder the real metallurgist. The reducing action in the furnace is effected almost entirely by the gases, and when these are allowed to go to waste, reduction ceases.