Repairs.—This item is quite small in works properly constructed; and in this connection I wish to call particular attention to the floor covering, which should be made of cast-iron plates from 1.5 to 2 in. thick, and placed on a 2 to 3 in. layer of sand spread over the well-tamped and leveled ground. The constant patching of brick floors is not only an annoyance, but is costly from the additional labor required. Furthermore, a brick floor does not permit a close saving of the metallic scrap material.
It will be found economical in the long run to protect all exposed brickwork of furnaces or kettles with sheet iron.
In the construction of the refinery building I should advise brick walls except at the end or side, where there is the greatest likelihood of future extension; here corrugated iron may be used. The roof should not be made of corrugated iron, as condensed or leakage water is liable to collect and drop on those places where water should be scrupulously avoided. The presence of water in a mold at the time of casting, even though small in amount, will cause explosions and will scatter the molten lead, endangering the workmen.
The item of repair for the ordinary corrugated iron roof may be diminished by constructing it of 1 in. boards with intervening spaces of half an inch, the whole overlaid with tarred felt, and covered with sheets of iron at least No. 27 B. W. G., painted with graphite paint and joined together with parallel rows of ribbed crimped iron.
General Expenses.—This item is generally constant, and calls for no special comment.
Interest.—This important item is, as a rule, considerable, as the stock of bullion and other gold-and silver-bearing material is quite large. For this reason special attention should be given to prevent the accumulation of stock or by-products. The occasional necessity of additional capital to run the business should preferably be met by an increase of working capital, rather than by a direct loan.
Expressage.—This item, as a rule, is large, and should be taken into consideration in the original plans for the location of the refining works.
Parting.—The item of parting and brokerage is the largest of the refinery costs, and for obvious reasons a modern smelting plant should have a parting plant under its own control.
The Working of the By-Products.—This constitutes a large item of cost, and considerable attention should be devoted to the improvement of present methods, which seem faulty, slow and expensive.
Summary.—The items of smaller cost with their respective amounts per ton of base bullion treated are: Spelter, $0.85; coal, $0.50; coke, $0.50; supplies, repairs and general expenses, $0.35; total, $2.10. It is doubtful whether much improvement can be made in the reduction of these costs.