That the roaster gases from the reverberatory-smelting and sintering furnaces did not show such a high percentage of sulphur dioxide must be ascribed chiefly to the circumstance that the roasting was much slower, and that the gases were largely diluted with air already at the point where they are formed, as the work must always be done with the working-doors open. In the Huntington-Heberlein process, on the other hand, the aim is to prevent, as far as possible, the access of air from outside while blowing the charge. The more perfectly this is effected, and the greater the quantity of ore to be blown in the converters, the higher will also be the percentage of sulphur dioxide in the waste gases. This circumstance has not only furnished the inducement, but it has rendered it possible to approach the plan of utilizing the sulphur dioxide for the manufacture of sulphuric acid. If this should be done successfully (which, according to the experiments carried out, there is reasonable ground to expect), the present disadvantage might be turned into an advantage. This has the more significance because an essential constituent of the lead ore—the sulphur—will then no longer, as hitherto, have to be regarded as wholly lost.[31]
THE HUNTINGTON-HEBERLEIN PROCESS
By Thomas Huntington and Ferdinand Heberlein
(May 26, 1906)
This process for roasting lead sulphide ores has now fairly established itself in all parts of the world, and is recognized by metallurgical engineers as a successful new departure in the method of desulphurization. It offers the great advantage over previous methods of being a more scientific application of the roasting reactions (of the old well-used formulæ PbS + 3O = PbO + SO2 and PbS + PbSO4 + 2O = 2PbO + 2SO2) and admits of larger quantities being handled at a time, so that the use of fuel and labor are in proportion to the results achieved, and also there is less waste all around in so far as the factors necessary for the operation—fuel, labor and air—can be more economically used. The workman’s time and strength are not employed in laboriously shifting the ore from one part of the furnace to another with a maximum amount of exertion and a minimum amount of oxidation. The fuel consumed acts more directly upon the ore during the first part of the process in the furnace and its place is taken by the sulphur itself during the final and blowing stage, so that during the whole series of operations more concentrated gases are produced and consequently the large excess of heated air of the old processes is avoided to such an extent that the gases can be used for the production of sulphuric acid.
With a modern well-constructed plant practically all the evils of the old hand-roasting furnaces are avoided, and besides the notable economy achieved by the H.-H. process itself, the health and well-being of the workmen employed are greatly advanced, so that where hygienic statistics are kept it is proved that lead-poisoning has greatly diminished. It is only natural, therefore, that the H.-H. process should have been a success from the start, popular alike with managers and workmen once the difficulties inseparable from the introduction of any new process were overcome.
Simple as the process now appears, however, it is the result of many years of study and experiment, not devoid of disappointments and at times appearing to present a problem incapable of solution. The first trials were made in the smelting works at Pertusola, Italy, as far back as 1889, where considerable sums were devoted every year to this experimental work and lead ore roasting was almost continuously on the list of new work from 1875 on.
It may be interesting to mention that at this time the Montevecchio ores (containing about 70 per cent. lead and about 15 per cent. sulphur, together with a certain amount of zinc and iron) were considered highly refractory to roast, and the only ores approved of by the management of the works at this date were the Monteponi and San Giovanni first-class ores (containing about 80 per cent. lead), and the second-class carbonates (with at least 60 per cent. lead and 5 per cent. sulphur). It must be noted that a modified Flintshire reverberatory process was in use in the works, which could deal satisfactorily only with this class of ore, so that, as these easy ores diminished in quantity every year and their place was taken by the “refractory” Montevecchio type, the roasting problem was always well to the front at the Pertusola works.