Fig. 11.—East Helena Charge-car. (Plan.)
The furnaces were running very hot on top when this modified procedure was begun. In a few hours the over-fire had disappeared; the lead output was increasing; and the furnaces were running normally. This was done about May 1, 1899, and from that time until about February 20, 1900, the Hixon feed, as modified above, was continuously in operation. In October, 1898, with three furnaces in operation and hand feeding, the labor cost per furnace was $42.06 per day; in October, 1899, with the same number of furnaces and mechanical feeding, it was $41 per day, the saving being only 0.6c. per ton of charge.
Fig. 12.—East Helena Charge-car and Transfer Carriage. (Elevation.)
Fig. 13.—East Helena System, with spreader and curtains. (Experimental form.)
Dwight Spreader and Curtain.—In January, 1900, the writer again had occasion to visit the East Helena plant, to investigate why a certain cheap local coke could not be used successfully instead of expensive Eastern coke. Strange as it may seem, the peculiar behavior of the cokes was traced to improper feeding of the furnaces. Further study of the mechanical feeding system, then in operation for nine months, showed that it was far from perfect, and it appeared desirable to design a spreader which would properly distribute the material discharged from the Hixon car and dispense with hand feeding entirely. An experimental construction was arranged, as shown in Fig. 13. The flanged cast-iron plates around the feeding slot were pushed back and a roof-shaped spreader, with slopes of 45 deg., was set in the gap, leaving openings about 8 in. wide on each side. The plan provided for two iron curtains to be hung, one on each side of the spreader, and so adjusted that the fine ore sliding down the spreader would clear the edge of the curtain and shoot toward the sides of the furnace, while the coarse ore would strike the curtain and rebound toward the center of the furnace. The classification effected in this manner was capable of adjustment by raising or lowering the curtain. This arrangement was found to work surprisingly well. The first furnace equipped with it immediately showed improvement. It averaged better in speed, with lower blast, lower lead in slag and matte, and better bullion output than the other furnaces operating under the old system. The success of the spreader and curtain being established, the furnaces were provided with permanent constructions, the only modifications being that the ridge of the spreader was lowered to correspond with the level of the floor and the curtains were omitted, the feeding being apparently satisfactory without their aid. In their absence, the lowering of the spreader was a proper step, as it distributed the material fully as well, and caused less abrasion of the walls. The final form is shown approximately in Fig. 14. It has given complete satisfaction at East Helena since February, 1900, and has been adopted as the basis for the mechanical feeding device in the new plant of the American Smelting and Refining Company at Salt Lake, Utah.
Fig. 14.—East Helena System. (Final form, approximate.)
Comparison of Systems.—In mechanical design the Pueblo system is better than the East Helena, being simpler in construction and operation. No time is lost in attaching and changing cables, operating transfer carriage, etc. In both systems the track runs directly over the tops of the furnaces, and this is an inconvenience when furnace repairs are under way. The Pueblo car is the simpler, and makes the round trip in about half the time of a car at East Helena, so the two cars of the latter do not make much difference in this respect. The system of filling the charge-car at Pueblo is also the quicker. It may be estimated roughly that per ton of capacity it takes 2.5 to 3 times as long to fill the East Helena car; and this means longer waiting on the part of the wheelers, and consequently greater cost of moving the material, representing probably 7 or 8c., in favor of Pueblo, per ton of charge handled. However, both systems are wasteful of labor. As to furnace results, it is believed that the better distribution of the charge in the East Helena system leads to greatly increased regularity of furnace running, less tendency to over-fire, some economy in fuel, less accretions on the furnace walls and larger metal savings. If the half of these conclusions are true, the difference of 7 or 8c. per ton in favor of the Pueblo system, which can be traced almost entirely to the cost of filling the charge-car, sinks into insignificance in comparison with the important advantages of having the furnaces uniformly and correctly fed.