Probably no revolving mechanical furnace is suited to the roasting of these ores, as the operation requires to be carefully and intelligently watched, for it is essential to the success of the Francke process that the ores should not be completely or "dead" roasted, inasmuch as certain salts, prejudicial to the ultimate proper working of the process, are liable to be formed if the roasting be too protracted. These salts are mainly due to the presence of antimony, zinc, lead, and arsenic, all of which are unfavorable to amalgamation.
The ores are roasted with 8 per cent. of salt, or 400 lb. of salt for the charge of 2½ tons of ore; the salt costs 70 cents, or 2s. 2d. per 100 lb. So roasted the ores are only partially chlorinized, and their complete chlorination is effected subsequently, during the process of amalgamation; the chlorides are thus formed progressively as required, and, in fact, it would almost appear that the success of the process virtually consists in obviating the formation of injurious salts. All the sulphide ores in Bolivia contain sufficient copper to form the quantity of cuprous chloride requisite for the first stages of roasting, in order to render the silver contained in the ore thoroughly amenable to subsequent amalgamation.
Amalgamating.—From the furnaces the roasted ore is taken in ore cars to large hoppers or bins situated immediately behind the grinding and amalgamating vats, locally known as "tinas," into which the ore is run from the bin through a chute fitted with a regulating slide. The tinas or amalgamating vats constitute the prominent feature of the Francke process; they are large wooden vats, shown in Figs. 1 and 2, page 173, from 6 ft. to 10 ft. in diameter and 5 ft. deep, capacious enough to treat about 2½ tons of ore at a time. Each vat is very strongly constructed, being bound with thick iron hoops. At the bottom it is fitted with copper plates about 3 in. thick, A in Fig. 1; and at intervals round the sides of the vat are fixed copper plates, as shown in Figs. 3 and 4, with ribs on their inner faces, slightly inclined to the horizontal, for promoting a more thorough mixing. It is considered essential to the success of the process that the bottom plates should present a clear rubbing surface of at least 10 square feet.
THE FRANCKE "TINA" PROCESS FOR THE AMALGAMATION OF SILVER ORES.
Within the vat, and working on the top of the copper plates, there is a heavy copper stirrer or muller, B, Figs. 1 and 2, caused to revolve by the shafting, C, at the rate of 45 revolutions per minute. At Huanchaca this stirrer has been made with four projecting radial arms, D D, Figs. 1 and 2; but at Guadalupe it is composed of one single bell-shaped piece, Figs. 3 and 4, without any arms, but with slabs like arms fixed on its underside; and this latter is claimed to be the most effective. The stirrer can be lifted or depressed in the vat at will by means of a worm and screw at the top of the driving shaft, Fig. 3.
The bevel gearing is revolved by shafting connected with pulley wheels and belting, the wheels being 3 ft. and 1½ ft. in diameter, and 6 in. broad. The driving engine is placed at one end of the building. Each vat requires from 2½ to 3 horse-power, or in other words, an expenditure of 1 horse-power per ton of ore treated.
At the bottom of the vat, and in front of it, a large wooden stop-cock is fitted, through which the liquid amalgam is drawn off at the end of the process into another shallow-bottomed and smaller vat, Figs. 1 and 2. Directly above this last vat there is a water hose, supplied with a flexible spout, through which a strong stream of water is directed upon the amalgam as it issues from the grinding vat, in order to wash off all impurities.
The following is the mode of working usually employed. The grinding vat or tina is first charged to about one-fifth of its depth with water and from 6 cwt. to 7 cwt. of common salt. The amount of salt required in the process depends naturally on the character of the ore to be treated, as ascertained by actual experiment, and averages from 150 lb. to 300 lb. per ton of ore. Into this brine a jet of steam is then directed, and the stirrer is set to work for about half an hour, until the liquid is in a thoroughly boiling condition, in which state it must be kept until the end of the process.
As soon as the liquid reaches boiling point, the stamped and roasted ore is run into the vat, and at the end of another half-hour about 1 cwt. of mercury is added, further quantities being added as required at different stages of the process. The stirring is kept up continuously for eight to twelve hours, according to the character and richness of the ores. At the end of this time the amalgam is run out through the stop-cock at bottom of the vat, is washed, and is put into hydraulic presses, by means of which the mercury is squeezed out, leaving behind a thick, pulpy mass, composed mainly of silver, and locally termed a "piña," from its resembling in shape the cone of a pine tree. These piñas are then carefully weighed and put into a subliming furnace, Figs. 5 and 6, in order to drive off the rest of the mercury, the silver being subsequently run into bars. About four ounces of mercury are lost for every pound of silver made.