In dressing mixed lead and zinc carbonate ores by the old method of gradual crushing with rolls, middling products were obtained, which could be further separated only with much loss. Inasmuch as the losses in the metallurgical treatment of such mixed ore were reckoned to be less than in ore dressing, these between-products at Monteponi were saved for a number of years, until there should be enough raw material to warrant the erection of a small lead and zinc smeltery.
In 1894 the lead smeltery in Monteponi was put in operation; in 1899 the zinc smeltery was started. At about the same time the reserves of lead ore were exhausted, and the lead plant then began to treat all the Monteponi ores and a part of those from neighboring mines.
As will be seen from the plan (Fig. 42), the smelting works cluster in terraces around the mine shaft, covering an area of about 3000 sq. m. (0.75 acre); the ore stocks and the pottery of the zinc works are located in separate buildings.
During the first years of working, the slag had purposely been kept very rich in zinc, in the hope of utilizing it later for the production of zinc oxide. It had an average zinc content of 16.80 per cent., or 21 per cent. of zinc oxide, with about 32 per cent. SiO2, 25 per cent. FeO, and 14 per cent. lime. According to the recent experiments, this slag can very well be used for oxide manufacture, in connection with calamine rich in iron. The slag made at the present time has only 15 per cent. ZnO; 25 per cent. SiO2; 16 per cent. CaO; 3 per cent. MgO; 33 per cent. FeO; 2.5 per cent. Al2O3, and 2 per cent. BaO, and small quantities of alkalies, sulphur and lead (1 to 1.5 per cent).
The following classes of ore are produced at Monteponi:
1. Lead carbonates, with a little zinc oxide; these ores are screened down to 10 mm. The portion held back by the screen is sent straight to the shaft furnaces; the portion passing through is either roasted together with lead sulphides, or is sintered by itself, according to circumstances.
2. Dry lead ores, mostly quartz, with 10 to 15 per cent. lead, which are mixed for smelting with the lead carbonates.
Fig. 42.—General Plan of Works.
3. Lead sulphides, which are crushed fine and roasted dead. Quartz sand is added in the roasting, in order to decompose the lead sulphate and produce a readily fusible silicate; as quartz flux, fine sand from the dunes on the coast is used. This is a product of decomposition of trachyte, and contains 88 per cent. of silica, together with alkalies and alumina. The roast is effected in two hand-raked reverberatory furnaces, 18 m. long, which turn out 12,000 kg. of roasted ore in 24 hours, consuming 1800 kg. of English cannel coal, or 2400 kg. of Sardinian lignite. There is also a third reverberatory furnace, provided with a fusion chamber, which is used for roasting matte and for liquating various secondary products.