improvements in the Process of apparWOULD Extraction of Metals from their Ores.
Year: 1884

page_text: improvements in the Process of
apparWOULD
Extraction of Metals from their Ores.
I, JAMES JOHN SHEDLOCK of Barnet in the County of Hertford, Engineer do
hereby declare the nature of my invention for "IMPROVEMENTS IN THE PROCESS
OF AND APPARATUS FOR THE EXTRACTION OF METALS FROM THEIR ORES
as follows:-
"
to be
For the
This Invention having for its object the treatment of ores for the separation of
their metals is carried into effect by passing the ore in a finely divided state mixed
with powdered carbon through a bath of any suitable molten metal maintained at
the temperature necessary to ensure its combination with any free metal contained
in the ore; but as most ores contain metals associated or in combination with the
metalloids it becomes necessary to decompose such compounds in order that the
metals may be freed and in such a condition as to readily combine with the metallic
batb. This is accomplished by forcing streams of reducing gases through the bath
of molten metal simultaneously with the pulverised ore and carbon, which are
conveyed into the bath at its end by suitable feeding apparatus, the action of which
is so regulated as to work in concert with the supply of reducing gases.
production of these gases, steam from any convenient source is passed through
superheaters the outlets of which communicate with gas producers charged with
materials possessing the property at elevated temperatures of readily combining
with oxygen, the most economical being those of a carbonaceous nature, thereby
producing carbonic-oxide and hydrogen gases which are conveyed from the gas
producers by tubes into the bath of molten metal. In consequence of the affinity
possessed by these gases for the metalloids and also by reason of their high
temperatures, the metallic compounds are decomposed and the volatile constituents
of the ore are vaporized which with the earthy or non-reducible portions by reason
of their lesser specific gravity rise to the surface of the bath of molten metal. The
gases and vapours are conveyed through flues into chambers where those that are
condensable are thrown down and collected, the permanent gases escaping into the
chimney shaft, and the earthy matters removed by skimming. The metals as they
accumulate in the bath overflow into receivers through spouts, the inner mouths of
which are so much below the surface of the metal as to prevent any dross from
passing over, the metals as they collect are run into ingots or bars. In treating

page_text: certain ores, more especially those containing the noble associated with the baser
metals, it.. may be desirable to refine those metals without removal from the bath,
for this purpose atmospheric air raised to the required temperature is forced through
the molten metal's contained in the bath, its passage being retarded by the inclined
cover thereby causing considerable agitation of the mass and subjection of the
metals and metalloids to the oxidising action of the heated air. The oxides and
other combinations thus formed with the vapours and gases rise to the surface,
and are removed and conveyed by the flues to the condensing chambers, the refined
metal being withdrawn from the bath and run into ingots. The superheaters, gas
producers and air heating chambers are enclosed in an oven into which the heated
products of combustion from the furnace enter and circulate, thereby raising the
temperature of the apparatus and its contents to the required degree, the furnace
gases then pass into the flues surrounding the bath containing the molten metals,
eventually escaping into the chimney shaft.
There are no exceptions of the ores which may be manipulated by this invention,
the most refractory as well as the most easily reduced being successfully treated by
its means, the ores of iron when subjected to the process for the extraction of that
metal being most readily reduced, and its direct conversion at one operation into
carbide of iron from the softest cast iron to the mildest steel, and at the same time
effecting the entire removal of all deleterious impurities.
The ores of zinc are also most readily treated by this process as a continuous
operation, the ore being fed into the apparatus and the metal as it is distilled over
passes away through the flues into the chambers where it is condensed and collected.
When found desirable the metals as they are extracted from their ores may be
alternately subjected to the action of the reducing gases and the heated atmos-
pheric air.
All the parts of the apparatus which are subjected to elevated temperatures
must of necessity be constructed in refractory materials, and the superheaters gas
producers and beated air chambers are provided with gas tight connections and
covers for the passage of the gases, supplying the necessary carbonaceous materials
thereto and the removal of the ash or earthy matters as they accumulate.
'
Dated him the tn of AT
1004

page_text: Extraction of Metals from their Ores.
I JAMES JOHN SHEDLOCK of Barnet in the County of Hereford Engineer do
hereby declare the nature of my invention for "IMPROVEMENTS IN THE PROCESS
OF AND APPARATUS FOR THE EXTRACTION OF METALS FROM THEIR ORES," and
in what manner the same is to be performed to be particularly described and
ascertained in and by the following statement:—
This invention having for its object the treatment of Ores for the separation of
their metals is carried into effect by passing the ore in a finely divided state mixed
with powdered carbon through a bath of any suitable molten metal maintained at
the temperature necessary to ensure its combination with any free metal contained
in the ore but as most Ores contain metals associated or in combination with the
metalloids it becomes necessary to decompose such compounds in order that the
metals may be freed and in such a condition as to readily combine with the metallic
bath. This is accomplished by forcing streams of reducing gases through the bath
of molten metal simultaneously with the pulverized ore and carbon which are
conveyed into the bath at its end by suitable feeding apparatus, the action of which
is so regulated as to work in concert with the supply of reducing gases.--For the
production of these gases steam from any convenient source is passed through
superheaters the outlets of which communicate with gas producers charged with
materials possessing the property at elevated temperatures of readily combining
with oxygen the most economical being those of a carbonaceous nature thereby
producing carbonic oxide and hydrogen gases which are conveyed from the gas
producers by tubes into the bath of molten metal.-In consequence of the affinity.
possessed by these gases for the metalloids and also by reason of their high
temperatures the metallic compounds are decomposed and the volatile constituents
of the ore are vaporized which with the earthy or non-reducible portions by reason
The
of their lesser specific gravity rise to the surface of the bath of molten metal.
gases and vapours are conveyed through flues into chambers where those that are
condensable are thrown down and collected the permanent gases escaping into the
chimney shaft and the earthy matters removed by skimming. The metals as they
accumulate in the bath overflow into receivers through spouts the inner mouths of
which are so much below the surface of the metal as to prevent any dross from
passing over the metals as they collect are run into ingots or bars.-In treating
certain ores more especially those containing the noble, associated with the baser
metals, it may be desirable to refine those metals without removal from the bath-
for this purpose atmospheric air raised to the required temperature is forced through
the molten metals contained in the bath, its passage being retarded by the inclined
cover, thereby causing considerable agitation of the mass and subjection of the
The oxides and
metals and metalloids to the oxidizing action of the heated air.
other combinations thus formed with the vapours and gases rise to the surface and
are removed and conveyed by the flues to the condensing chambers the refined
metal being withdrawn from the bath and run into ingots. The superheaters gas
producers and air heating chambers are enclosed in an oven into which the heated
products of combustion from the furnace enter and circulate thereby raising the
temperature of the apparatus and its contents to the required degree the furnace

page_text: gases then pass into the flues surrounding the bath containing the molten metals
eventually escaping into the chimney shaft.
There are no exceptions of the ores which may be manipulated by this invention
the most refractory as well as the most easily reduced being successfully treated by
its means the ores of iron when subjected to the process for the extraction of that
metal being most readily reduced and its direct conversion at one operation into
the different carbides of iron varying from the softest cast iron to the mildest steel
and at the same time effectually removing all deleterious impurities.
The ores of zinc are also most readily treated by this process as a continuous
operation the ore being fed into the apparatus and the metal as it is distilled over
passes away through the flues into the chambers where it is condensed and col-
lected. When found desirable the metals as they are extracted from their ores
may be alternately subjected to the action of the reducing gases and the heated
atmospheric air.
All the parts of the apparatus which are subjected to elevated temperatures
must of necessity be constructed in refractory materials and the superheaters gas
producers and heated air chambers are provided with gas tight connections and
covers for the passage of the gases supplying the necessary carbonaceous materials
thereto and the removal of the ash or earthy matters as they accumulate.
The accompanying Drawing illustrates an apparatus suitable for carrying out
the objects of this invention. Figure 1 is a plan partly in section. Figure 2 is
a longitudinal section. Figure 3 is an elevation partly in section and Figure 4 is
a transverse section. Similar letters of reference indicate the same parts where
such parts appear in each of the figures.
The bath A has its bottom inclined from the back to the front and the greater
part of its top is covered by a plate or slab M which rises from the rear to the
front end leaving an opening N at the front of the bath A.-The bath filled with
any suitable molten metal is maintained at the required temperature by the heated
gases from the furnace B which first pass round and heat the gas generators H H
and super heaters I I and then through the flues C C C which surround the bath A
thence into the chimney shaft S. The furnace B is supplied with flue at the
opening D which is fitted with an air tight cover E and the oxygen necessary for
supporting combustion of the fuel is supplied by the atmospheric air which is
admitted by the narrow opening X at the bottom of the furnace and the channels
UU formed in the sides of the furnace. The atmospheric air is regulated in
passing through the channels U U and becomes highly heated before entering the
combustion chambers where the gases from the fuel are thoroughly oxidised
ensuring perfect combustion with highest attainable heat.-The vertical gas
generators H H are supplied with carbonaceous or other suitable materials at
the openings fitted with gas tight covers T T-Steam from any convenient source
is conveyed into the superheaters I I by the pipes and valves J J by which means
the passage of the steam is regulated to the quantity required for producing the
decomposing gases. The highly heated steam after passing through the channels
formed in the superheaters I I escapes by the openings Z Z into the chambers KK
with which the lower ends of the gas generators H H communicate and in passing
upward through the incandescent carbonaceous materials becomes decomposed its
oxygen combines with the carbon to form carbonic oxide which with the liberated
hydrogen pass from the gas generators by the gas ways L L into the bath of inolten
metal A. The pulverized ore mixed with the required proportion of powdered
carbon is fed into the hopper F at the bottom of which is an opening communi-
cating with the feeding apparatus G the screw of which when made to revolve
carries the pulverized ore into and through the bath of molten metal in most
intimate contact and association with the reducing gases entering by the gas
ways L L. The reducing gases being forced into the Bath of molten metal there
is a considerable agitation of the mass and consequently the most perfect inter-i
mixing of the pulverized ore and reducing gases take place thereby reducing the
metals contained in the ore which combine with the metal of the bath and cause

page_text: the metalloids and the earthy or non-reducible constituents of the ore to rise to
the surface of the bath and pass along the underside of the cover M to the opening N
where they are removed or escape into the flue O thence into the condensing
chambers. The length and inclination of the slab or cover M may be so regulated
as to cause the ore and gases on their passage through the bath of molten metal to
be retarded or made to travel forward at such a speed that the ore is kept under
the influence of the reducing gases sufficiently long to perfectly decompose the
combinations and allow the metals to combine or alloy themselves with the metal
of the bath. The metals as they accumulate in the bath A may be allowed to
overflow at the spout Q the inner mouth of which is so far below the level of the
molten metal as to prevent any dross from passing over with the metals as they
flow into the receiver R. When it is found desirable or for the purpose of refining
the metals contained in the bath A by removing the oxidizing metals then the
gas generators H H are filled. with refractory instead of carbonaceous materials and
atmospheric air is driven through the pipes J J the super heaters I I and the gas
generators H H and in its passage becomes highly heated and in a state as it
issues from the gas ways L L into the Bath of molten metal A to rapidly oxidize
the baser metals driving off those which are volatile into the condensing chambers
where they are collected and removed as desired. The refined metal may then be
withdrawn from the bath by the tapping hole W and run into ingots or bars.
The earthy or non-reducible constituents of the ore as they rise to the surface of
the bath of molten metal at the opening N are removed at the door P and the
ash or earthy matter from the carbonaceous materials with which the gas gene-
rators H H are charged falls into and accumulates in the chambers K K from
whence it is removed by the doors V V. Those parts of the apparatus which are
subjected to elevated temperatures must be constructed in refractory materials.
Having now particularly described and ascertained the nature of my said
invention and in what manner the same is to be performed I desire to say that
modifications may be made in the apparatus without departing from its essential
features, but what I claim is
1. The improved process for reducing and separating metals from their ores
consisting in passing the ore with or without carbon in a finely divided state
through a bath of molten metal along with reducing gases which under pressure
enter the molten metal at or near where the pulverized ore enters the same
and pass through the molten metal simultaneously therewith substantially as
described.
2. In a process for reducing and separating metals from their ores passing the
ore with or without carbon in a pulverized state through molten metal with
hydrogen and carbonic oxide gases produced by passing superheated steam through
heated carbonaceous or other materials and applied under pressure to the ore as it
enters the molten metal substantially as set forth.
3. In combination a bath having an inclined top filled with a molten metal,
a feeding device for forcing the pulverized ore into the molten metal, at the lower
end of the inclined top of the bath, and gas generators whose outlets communicate
with the bath of molten metal at or near where the pulverized ore enters the same,
substantially as and for the purpose set forth.
4. In an apparatus for treating ores in combination, the furnace B, gas
generators H, steam superheaters I, bath A, and ore feeder F G, substantially as
set forth,