COST OF HAND-ROASTING PER TON (2000 LB.) OF ORE
| 1887 | $3.975 | │ | 1893 | — |
| 1888 | 4.280 | │ | 1894 | 3.429 |
| 1889 | 4.120 | │ | 1895 | 2.806 |
| 1890 | 3.531 | │ | 1896 | 2.840 |
| 1891 | 3.530 | │ | 1897 | 2.740 |
| 1892 | — | │ | 1898 | 2.620 |
At first the roasting was done mainly by hand roasters; later two Brown-O’Harra mechanical furnaces were used, and the cost was reduced, but not to the extent usually conceded to this type of furnace, as the large amount of repairs and the consequent loss of time diminished the apparent gain due to greater output. The figures quoted above may be considered somewhat higher than the average, as the roasters were charged in proportion with expenses of general management, office, etc.
In viewing the yearly reduction of costs one must take into consideration many changes in the furnace construction and working, as well as the items of labor, fuel, etc. From 1887 to 1899 the principal changes in the construction of the hand-roasting furnaces consisted in an increase of width, 2 ft., which allowed an addition of 200 lb. to each ore charge, and corresponded to a total increase per furnace of 1200 lb. in 24 hours. In the working of the charge an important change was made in the condition of the product. Formerly the material was fused in the fusion-box and drawn from the furnace in a fused or slagged condition; and while this gave an excellent material for the subsequent treatment in the shaft furnace in that there was very little dusting of the charge, and a considerable increase in the output of the furnace, the disadvantages of large losses of lead and silver greatly over-balanced the advantages, and called for an entire abandonment of the fusion-box. As a result of experience it was found that the best condition of product is a semi-fused or sintered state, in which the particles of roasted ore have been compressed by pounding the material, which has been drawn into the slag pots, with a heavy iron disk. The amount of “fines” under these conditions is quite small and depends upon the percentage of lead in the ore, the degree of heat employed, and the extent of the compression.
The total cost was partly reduced from the lessened labor cost following the financial disturbance of 1893, and partly from the reduction in the fuel cost, the former expensive lump coal being replaced by the slack coals from southern Colorado.
The comparison of the cost of labor by the two methods shows a gain of 54c. a ton in favor of the mechanical furnaces. However, I consider that this gain is a costly one, and is more than offset by the large amount of high-grade fuel required, and the expense of repairs not shown in the following table. Indeed, I believe that at the end of five or ten years the average cost of roasting per ton by the hand roasters will be even smaller than by these mechanical roasters.
To illustrate the details of roasting cost and to furnish a comparison of the hand roasters and mechanical furnaces, the following table has been prepared:
DETAILS OF AVERAGE MONTHLY COST FOR 1898 OF HAND ROASTERS AND MECHANICAL FURNACES