| Locality. | Year. | Tuyère Section. | Height, Tuyère to Throat. |
| In. | Ft. | ||
| Leadville, Colorado | 1880 | 33 × 84 | 14 |
| Denver, Colorado | 1880 | 36 × 100 | 17 |
| Durango, Colorado | 1882 | 36 × 96 | 12.6 |
| Denver, Colorado | 1892 | 42 × 100 | 16 |
| Leadville, Colorado | 1892 | 42 × 120 | 18 |
| Salt Lake City, Utah | 1895 | 45 × 140 | 20 |
A furnace, 42 by 120 in. at the tuyères, with a working height of 17-20 ft., will put through in twenty-four hours, with twelve men, 12% coke and 2 ℔ blast-pressure, 85-100 tons average charge, i.e. one that is a medium coarse, contains 12-15% lead, not over 5% zinc, and makes under 5% matte. In making up a charge, the ores and fluxes, whose chemical compositions have been determined, are mixed so as to form out of the components not to be reduced to the metallic or sulphide state, typical slags (silicates of ferrous and calcium oxides, incidentally of aluminium oxide, which have been found to do successful work). Such slags contain SiO2 = 30-33%, Fe(Mn)O = 27-50%, Ca(Mg, Ba)O = 12-28%, and retain less than 1% lead and 1 oz. silver to the ton. The leading products of the blast-furnace are argentiferous lead (base bullion), matte, slag and flue-dust (fine particles of charge and volatilized metal carried out of the furnace by the ascending gas current). The base bullion (assaying 300 ± oz. per ton) is desilverized (see below); the matte (Pb = 8-12%, Cu = 3-4%, Ag = 1⁄3-1⁄5 of the assay-value of the base bullion, rest Fe and S) is roasted and resmelted, when part of the argentiferous lead is recovered as base bullion, while the rest remains with the copper, which becomes concentrated in a copper-matte (60% copper) to be worked up by separate processes. The slag is a waste product, and the flue-dust, collected by special devices in dust-chambers, is briquetted by machinery, with lime as a bond, and then resmelted with the ore-charge. The yield in lead is over 90%, in silver over 97% and in gold 100%. The cost of smelting a ton of ore in Colorado in a single furnace, 42 by 120 in. at the tuyères, is about $3.
The lead produced in the reverberatory furnace and the ore-hearth is of a higher grade than that produced in the blast-furnace, as the ores treated are purer and richer, and the reducing action is less powerful. The following analysis of blast-furnace Refining. lead of Freiberg, Saxony, is from an exceptionally impure lead: Pb = 95.088, Ag = 0.470, Bi = 0.019, Cu = 0.225, As = 1.826, Sb = 0.958, Sn = 1.354, Fe = 0.007, Zn = 0.002, S = 0.051. Of the impurities, most of the copper, nickel and copper, considerable arsenic, some antimony and small amounts of silver are removed by liquation. The lead is melted down slowly, when the impurities separate in the form of a scum (dross), which is easily removed. The purification by liquation is assisted by poling the lead when it is below redness. A stick of green wood is forced into it, and the vapours and gases set free expose new surfaces to the air, which at this temperature has only a mildly oxidizing effect. The pole, the use of which is awkward, has been replaced by dry stream, which has a similar effect. To remove tin, arsenic and antimony, the lead has to be brought up to a bright-red heat, when the air has a strongly oxidizing effect. Tin is removed mainly as a powdery mixture of stannate of lead and lead oxide, arsenic and antimony as a slagged mixture of arsenate and antimonate of lead and lead oxide. They are readily withdrawn from the surface of the lead, and are worked up into antimony (arsenic)—tin-lead and antimony-lead alloys. Liquation, if not followed by poling, is carried on as a rule in a reverberatory furnace with an oblong, slightly trough-shaped inclined hearth; if the lead is to be poled it is usually melted down in a cast-iron kettle. If the lead is to be liquated and then brought to a bright-red heat, both operations are carried on in the same reverberatory furnace. This has an oblong, dish-shaped hearth of acid or basic fire-brick built into a wrought-iron pan, which rests on transverse rails supported by longitudinal walls. The lead is melted down at a low temperature and drossed. The temperature is then raised, and the scum which forms on the surface is withdrawn until pure litharge forms, which only takes place after all the tin, arsenic and antimony have been eliminated.
Silver is extracted from lead by means of the process of cupellation. Formerly all argentiferous lead had to be cupelled, and the resulting litharge then reduced to metallic lead. In 1833 Pattinson invented his process by means of which practically all the Desilverizing. silver is concentrated in 13% of the original lead to be cupelled, while the rest becomes market lead. In 1842 Karsten discovered that lead could be desilverized by means of zinc. His invention, however, only took practical form in 1850-1852 through the researches of Parkes, who showed how the zinc-silver-lead alloy formed could be worked and the desilverized lead freed from the zinc it had taken up. In the Parkes process only 5% of the original lead need be cupelled. Thus, while cupellation still furnishes the only means for the final separation of lead and silver, it has become an auxiliary process to the two methods of concentration given. Of these the Pattinson process has become subordinate to the Parkes process, as it is more expensive and leaves more silver and impurities in the market lead. It holds its own, however, when base bullion contains bismuth in appreciable amounts, as in the Pattinson process bismuth follows the lead to be cupelled, while in the Parkes process it remains with the desilverized lead which goes to market, and lead of commerce should contain little bismuth. At Freiberg, Saxony, the two processes have been combined. The base bullion is imperfectly Pattinsonized, giving lead rich in silver and bismuth, which is cupelled, and lead low in silver, and especially so in bismuth, which is further desilverized by the Parkes process.
The effect of the two processes on the purity of the market lead is clearly shown by the two following analyses by Hampe, which represent lead from Lautenthal in the Harz Mountains, where the Parkes process replaced that of Pattinson, the ores and smelting process remaining practically the same:—
| Process. | Pb. | Cu. | Sb. | As. | Bi. | Ag. | Fe. | Zn. | Ni. |
| Pattinson | 99.966200 | 0.015000 | 1.010000 | none | 0.000600 | 0.002200 | 0.004000 | 0.001000 | 1.001000 |
| Parkes | 99.983139 | 0.001413 | 0.005698 | none | 0.005487 | 0.000460 | 0.002289 | 0.000834 | 0.000680 |
The reverberatory furnace commonly used for cupelling goes by the name of the English cupelling furnace. It is oblong, and has a fixed roof and a movable iron hearth (test). Formerly the test was lined with bone-ash; at present the hearth Cupelling. material is a mixture of crushed limestone and clay (3:1) or Portland cement, either alone or mixed with crushed fire-brick; in a few instances the lining has been made of burnt magnesite. In the beginning of the operation enough argentiferous lead is charged to fill the cavity of the test. After it has been melted down and brought to a red heat, the blast, admitted at the back, oxidizes the lead and drives the litharge formed towards the front, where it is run off. At the same time small bars of argentiferous lead, inserted at the back, are slowly pushed forward, so that in melting down they may replace the oxidized lead. Thus the level of the lead is kept approximately constant, and the silver becomes concentrated in the lead. In large works the silver-lead alloy is removed when it contains 60-80% silver, and the cupellation of the rich bullion from several concentration furnaces is finished in a second furnace. At the same time the silver is brought to the required degree of fineness, usually by the use of nitre. In small works the cupellation is finished in one furnace, and the resulting low-grade silver fined in a plumbago crucible, either by overheating in the presence of air, or by the addition of silver sulphate to the melted silver, when air or sulphur trioxide and oxygen oxidize the impurities. The lead charged contains about 1.5% lead if it comes from a Pattinson plant, from 5-10% if from a Parkes plant. In a test 7 ft. by 4 ft. 10 in. and 4 in. deep, about 6 tons of lead are cupelled in twenty-four hours. A furnace is served by three men, working in eight-hour shifts, and requires about 2 tons of coal, which corresponds to about 110 gallons reduced oil, air being used as atomizer. The loss in lead is about 5%. The latest cupelling furnaces have the general form of a reverberatory copper-smelting furnace. The working door through which the litharge is run off lies under the flue which carries off the products of combustion and the lead fumes, the lead is charged and the blast is admitted near the fire-bridge.
In the Pattinson process the argentiferous lead is melted down in the central cast iron kettle of a series 8-15, placed one next to the other, each having a capacity of 9-15 tons and a separate fire-place. The crystals of impoverished lead which fall Pattinson process. to the bottom, upon coaling the charge, are taken out with a skimmer and discharged into the neighbouring kettle (say to the right) until about two-thirds of the original charge has been removed; then the liquid enriched lead is ladled into the kettle on the opposite side. To the kettle, two-thirds full of crystals of lead, is now added lead of the same tenor in silver, the whole is liquefied, and the cooling, crystallizing, skimming and ladling are repeated. The same is done with the kettle one-third filled with liquid lead, and so on until the first kettle contains market lead, the last cupelling lead. The intervening kettles contain leads with silver contents ranging from above market to below cupelling lead. The original Pattinson process has been in many cases replaced by the Luce-Rozan process (1870), which does away with arduous labour and attains a more satisfactory crystallization. The plant consists of two tilting oval metal pans (capacity 7 tons), one cylindrical crystallizing pot (capacity 22 tons), with two discharging spouts and one steam inlet opening, two lead moulds (capacity 3½ tons), and a steam crane. Pans and pot are heated from separate fire-places. Supposing the pot to be filled with melted lead to be treated, the fire is withdrawn beneath and steam introduced. This cools and stirs the lead when crystals begin to form. As soon as two-thirds of the lead has separated in the form of crystals, the steam is shut off and the liquid lead drained off through the two spouts into the moulds. The fire underneath the pot is again started, the crystals are liquefied, and one of the two pans, filled with melted lead, is tilted by means of the crane and its contents poured into the pot. In the meantime the lead in the moulds, which has solidified, is removed with the crane and stacked to one side, until its turn comes to be raised and charged into one of the pans. The crystallization proper lasts one hour, the working of a charge four hours, six charges being run in twenty-four hours.
It is absolutely necessary for the success of the Parkes process that the zinc and lead should contain only a small amount of impurity. The spelter used must therefore be of a good grade, and the lead is usually first refined in a reverberatory Parkes process. furnace (the softening furnace). The capacity of the furnace must be 10% greater than that of the kettle into which the softened lead is tapped, as the dross and skimmings formed amount to about 10% of the weight of the lead charged. The kettle is spherical, and is suspended over a fire-place by a broad rim resting on a wall; it is usually of cast iron. Most kettles at present hold 30 tons of lead; some, however, have double that capacity. When zinc is placed on the lead (heated to above the melting-point of zinc), liquefied and brought into intimate contact with the lead by stirring, gold, copper, silver and lead will combine with the zinc in the order given. By beginning with a small amount of zinc, all the gold and copper and some silver and lead will be alloyed with the zinc to a so-called gold—or copper—crust, and the residual lead saturated with zinc. By removing from the surface of the lead this first crust and working it up separately (liquating, retorting and cupelling), doré silver is obtained. By the second addition of zinc most of the silver will be collected in a saturated zinc-silver-lead crust, which, when worked up, gives fine silver. A third addition becomes necessary to remove the rest of the silver, when the lead will assay only 0.1 oz. silver per ton. As this complete desilverization is only possible by the use of an excess of zinc, the unsaturated zinc-silver-lead alloy is put aside to form part of the second zincking of the next following charge. In skimming the crust from the surface of the lead some unalloyed lead is also drawn off, and has to be separated by an additional operation (liquation), as, running lower in silver than the crust, it would otherwise reduce its silver content and increase the amount of lead to be cupelled. A zincking takes 5-6 hours; 1.5-2.5% zinc is required for desilverizing. The liquated zinc-silver-lead crust contains 5-10% silver, 30-40% zinc and 65-50% lead. Before it can be cupelled it has to be freed from most of the zinc, which is accomplished by distilling in a retort made of a mixture similar to that of the plumbago crucible. The retort is pear-shaped, and holds 1000-1500 lb of charge, consisting of liquated crust mixed with 1-3% of charcoal. The condenser commonly used is an old retort. The distillation of 1000 ℔ charge lasts 5-6 hours, requires 500-600 ℔ coke or 30± gallons reduced oil, and yields about 10% metallic zinc and 1% blue powder—a mixture of finely-divided metallic zinc and zinc oxide. About 60% of the zinc used in desilverizing is recovered in a form to be used again. One man serves 2-4 retorts. The desilverized lead, which retains 0.6-0.7% zinc, has to be refined before it is suited for industrial use. The operation is carried on in a reverberatory furnace or in a kettle. In the reverberatory furnace, similar to the one used in softening, the lead is brought to a bright-red heat and air allowed to have free access. The zinc and some lead are oxidized; part of the zinc passes off with the fumes, part is dissolved by the litharge, forming a melted mixture which is skimmed off and reduced in a blast-furnace or a reverberatory smelting furnace. In the kettle covered with a hood the zinc is oxidized by means of dry steam, and incidentally some lead by the air which cannot be completely excluded. A yellowish powdery mixture of zinc and lead oxides collects on the lead; it is skimmed off and sold as paint. From the reverberatory furnace or the kettle the refined lead is siphoned off into a storage (market) kettle after it has cooled somewhat, and from this it is siphoned off into moulds placed in a semi-circle on the floor. In the process the yield in metal, based upon the charge in the kettle, is lead 99%, silver 100+%, gold 98-100%. The plus-silver is due to the fact that in assaying the base bullion by cupellation, the silver lost by volatilization and cupel-absorption is neglected. In the United States the cost of desilverizing a ton base bullion is about $6.
Properties of Lead.—Pure lead is a feebly lustrous bluish-white metal, endowed with a characteristically high degree of softness and plasticity, and almost entirely devoid of elasticity. Its breaking strain is very small: a wire 1⁄10th in. thick is ruptured by a charge of about 30 ℔. The specific gravity is 11.352 for ingot, and from 11.354 to 11.365 for sheet lead (water of 4°C. = 1). The expansion of unit-length from 0°C. to to 100°C. is .002948 (Fizeau). The conductivity for heat (Wiedemann and Franz) or electricity is 8.5, that of silver being taken as 100. It melts at 327.7°C. (H. L. Callendar); at a bright-red heat it perceptibly vapourizes, and boils at a temperature between 1450° and 1600°. The specific heat is .0314 (Regnault). Lead exposed to ordinary air is rapidly tarnished, but the thin dark film formed is very slow in increasing. When kept fused in the presence of air lead readily takes up oxygen, with the formation at first of a dark-coloured scum, and then of monoxide PbO, the rate of oxidation increasing with the temperature.