IMPROVEMENTS IN SMELTING COPPER AND OTHER METALS, AND IN FURNACES FOR SMELTING COPPER AND OTHER METALS AND FOR OTHER PURPOSES, AND IN OBTAINING PRODUCTS FROM THE GASES AND VAPOURS GIVEN OFF DURING THE SMELTING OF COPPER AND OTHER METALS
Year: 1868

page_text: LETTERS PATENT to Henry Causer Ensell, of St. Helen's, in the
County of Lancaster, Glass Manufacturer, for the Invention of
"IMPROVEMENTS IN SMELTING COPPER AND OTHER METALS, AND IN FURNACES
FOR SMELTING COPPER AND OTHER METALS AND FOR OTHER PURPOSES, AND
IN OBTAINING PRODUCTS FROM THE GASES AND VAPOURS GIVEN OFF DURING
THE SMELTING OF COPPER AND OTHER METALS."
Sealed the 20th November 1868, and dated the 20th August 1868.
PROVISIONAL SPECIFICATION left by the said Henry Causer Ensell
at the Office of the Commissioners of Patents, with his Petition,
on the 20th August 1868.
I, HENRY CAUSER ENSELL, of St. Helen's, in the County of Lancaster,
Glass Manufacturer, do hereby declare the nature of the said Invention
for "IMPROVEMENTS IN SMELTING COPPER AND OTHER METALS, AND IN FURNACES
FOR SMELTING COPPER AND OTHER METALS AND FOR OTHER PURPOSES, AND IN
OBTAINING PRODUCTS FROM THE GASES AND VAPOURS GIVEN OFF DURING THE
SMELTING OF COPPER AND OTHER METALS," to be as follows:-
My Invention consists of improvements on an Invention for which
Letters Patent were granted to me on the 18th day of December 1865,

page_text: No. 3267, and I will describe my present Invention in connection with
the improvements described in the Specification of the said Patent.
In smelting copper according to my Invention I use gaseous fuel
obtained by igniting or heating coal in a furnace or closed chamber or
retort, or I use inflammable gas obtained from coal, oil, resin, or other
substance from which inflammable gas can be obtained. In using the
said gaseous fuel it is passed through tubes or conduits, which can be
heated if desired so as to heat the gaseous fuel. By means of other
tubes or conduits nitrous gas or oxygen and atmospheric air, either hot
or cold, can be mixed with the gaseous fuel. The air and gases are
introduced into the furnace either at atmospheric pressure or at a
pressure higher than that of the atmosphere by means of fans or other
blowing apparatus. The pipes or conduits are provided with dampers or
valves, by means of which the quantity of gases or vapours and the
temperature of the same may be regulated at pleasure. By the com-
bustion of the gaseous mixture described an intense heat is produced,
the combustion being effected in the reverberatory furnace in which the
copper ore to be smelted is contained. The vapours and gases from the
smelting furnace descend into a covered space containing a layer or
layers of peroxide of iron in the state of bog iron ore or bog ochre, or in
any other convenient form, together with baryta or other absorbent
substance according to the nature of the gases and vapours given off by
the furnace. The said gases and vapours after having been brought into
contact with and yielded up to the peroxide of iron or other substance
employed, such of their constituents as have an affinity therefor, the said
gases and vapours are conducted to towers, in which are trays or bars
supporting layers of the materials used for treating the gases and
vapours that is principally peroxide of iron and baryta. The gases
and vapours may be forced through these towers by a fan or blowing
machine, and streams or jets of water may be employed in the said
towers to facilitate the absorption of the gases and vapours. Any con-
densible matters which escape absorption in the towers are made to pass
through pipes or conduits containing nitrous acid gas and steam into a
chamber or chambers, such as are commonly used for the manufacture
of sulphuric acid.
The improvements herein-before described may be applied to any of
the processes whereby copper or copper ores or compounds of copper are
treated, as well as to the treatment of compounds of other metals, and for

page_text: collecting or condensing any volatile matter which may be given off in
the treatment of the said copper or copper compounds, or compounds of
other metals.
My improvements may also be applied to kilns or furnaces for burning
or glazing earthenware, bricks, tiles, or pipes, and for other like
purposes.
SPECIFICATION in pursuance of the conditions of the Letters Patent,
filed by the said Henry Causer Ensell in the Great Seal Patent
Office on the 15th February 1869.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, HENRY
CAUSER ENSELL, of St. Helen's, in the County of Lancaster, Glass
Manufacturer, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her
Letters Patent, bearing date the Twentieth day of August, in the year
of our Lord One thousand eight hundred and sixty-eight, in the
thirty-second year of Her reign, did, for Herself, Her heirs and successors,
give and grant unto me, the said Henry Causer Ensell, Her special
licence that I, the said Henry Causer Ensell, my executors, adminis-
trators, and assigns, or such others as I, the said Henry Causer Ensell,
my executors, administrators, and assigns, should at any time agree
with, and no others, from time to time and at all times thereafter
during the term therein expressed, should and lawfully might make,
use, exercise, and vend, within the United Kingdom of Great Britain
and Ireland, the Channel Islands, and Isle of Man, an Invention for
"IMPROVEMENTS IN SMELTING COPPER AND OTHER METALS, AND IN FURNACES
FOR SMELTING COPPER AND OTHER METALS AND FOR OTHER PURPOSES, AND IN
OBTAINING PRODUCTS FROM THE GASES AND VAPOURS GIVEN OFF DURING THE
SMELTING OF COPPER AND OTHER METALS," upon the condition (amongst
others) that I, the said Henry Causer Ensell, my executors or adminis-
trators, by an instrument in writing under my, or their, or one of
their hands and seals, should particularly describe and ascertain the
nature of the said Invention, and in what manner the same was to
be performed, and cause the same to be filed in the Great Seal
Patent Office within six calendar months next and inmediately after
the date of the said Letters Patent.

page_text: NOW KNOW YE, that I, the said Henry Causer Ensell, do hereby
declare the nature of the said Invention, and in what manner the
same is to be performed, to be particularly described and ascertained
in and by the following statement thereof, that is to say :-
:
My Invention consists of improvements on an Invention for which
Letters Patent were granted to me on the 18th day of December 1865,
No. 3267, and I will describe my present Invention in connection with
the improvements described in the Specification of the said Patent.
In smelting copper according to my Invention I. use gaseous fuel
obtained by igniting or heating coal in a furnace or closed chamber or
retort, or I use inflammable gas obtained from coal, oil, resin, or other
substance from which inflammable gas can be obtained. In using the
said gaseous fuel it is passed through tubes or conduits which can be
heated so as to heat the gascous fuel. By means of other tubes or
conduits nitrous gas or oxygen or atmospheric air, either combined or
separately, and either hot or cold, can be mixed with the gaseous fuel.
The air and gases are introduced into the furnace either at atmospheric
pressure or at a pressure higher than that of the atmosphere by means of
fans or other blowing apparatus. The pipes or conduits are provided
with dampers or valves by means of which the quantity of gases or
vapours and the temperature of the same may be regulated at pleasure..
By the combustion of the gaseous mixture described an intense heat is.
produced, the combustion being effected in the reverberatory furnace in.
which the copper ore to be smelted is contained. The vapours and gases
from the smelting furnace descend into a covered space containing a
layer or layers of peroxide of iron in the state of bog iron ore or bog.
ochre, or in any other convenient form, together with baryta or other
absorbent substance, according to the nature of the gases and vapours.
given off by the furnace. The said gases and vapours after having been.
brought into contact with and yielded up. to the peroxide of iron or
other substance employed, such of their constituents as have an affinity
therefor, the said gases and vapours are conducted to towers in which
are trays or bars supporting layers of the materials used for treating the
gases and vapours that is principally peroxide of iron and baryta. The
a fan or
gases and vapours may be forced through these towers by
blowing machine, and streams or jets of water may be employed in the.
said towers to facilitate the absorption of the gases and vapours. Any
condensible matters which escape absorption in the towers are made to

page_text: pass through pipes or conduits containing nitrous acid gas and steam
into a chamber or chambers such as are commonly used for the manu-
facture of sulphuric acid. The improvements herein-before described
may be applied to any of the processes whereby copper or copper ores
or compounds of copper are treated as well as to the treatment of com-
pounds of other metals, and for collecting or condensing any volatile
matter which may be given off in the treatment of the said copper or
copper compounds or compounds of other metals. My improvements
may also be applied to kilus or furnaces for burning or glazing earthen-
ware, bricks, tiles, or pipes, and for other like purposes.
Having explained the nature of my said Invention I will proceed to
describe, with reference to the accompanying Drawing, the manner in
which the same is to be performed.
Figure 1 represents in longitudinal section, and Figure 2 in cross
section a gas-producing furnace or still for producing gaseous fuel con-
structed according to my Invention; Figure 3 is a plan of a portion of
the same. The gas furnace or producer or still a consists of a chamber
having an incline b down which the coal or solid fuel passes from the
hoppers c; d, are grate bars on which the fuel is received, and on which
it undergoes partial combustion. The gascous fuel produced in the
furnace producer or still a consists essentially of carbonic oxide and.
nitrogen, and passes by conduits to the copper smelting or other furnace
hereafter described to be mixed with air and there burnt. The said
gaseous fuel may either pass from the producer a through conduits of the
kind represented in Figure 1, and marked e, that is, conduits raised some
distance above the level of the ground, or by conduits at or about the
level of the ground, as indicated in dotted lines at d. When the gaseous
fuel is transmitted through conduits of the kind marked e it is cooled,
and any solid matter carried by it is deposited in the said conduit e.
At e, e, doors or valves may be placed, by opening which the conduit e
may be cleared of any matter deposited in it. The gascous fuel passes
from the conduit d² or e through the chamber or reservoir f to the
passage through the valve h, which is counterbalanced and raised and
lowered in any convenient manner, and the opening or closing of which
valve determines the quantity of the said gaseous fuel passing into the'
passage g. The atmospheric air which together with the gascous fuel is
conducted to the copper smelting or other furnace is heated before
passing to the said furnace by means of the producer or still a. The

page_text: atmospheric air supplied to the said furnace passes through channels i, i,
formed at the sides and at the back of the fire-bars d of the producer or
still a, and in its passage through the said channels becomes heated.
The said heated air passes to the furnace by conduits or channels which
may either be in the position marked k in Figure 1 or may run parallel
with the gas conduit d³, Figure 1.
Figure 4 represents in longitudinal section, Figure 5 in horizontal
section, and Figure 6 in transverse section a copper smelting or other
reverberatory furnace constructed according to my Invention to be
heated by the gaseous fuel and heated air produced in the manner
herein-before described. The said gaseous fuel entering the pit or
reservoir from the producer or still passes by the channel m under-
neath the furnace to the back of the said furnace. The said gaseous
fuel rising up the vertical channel n returns by the horizontal channel o
to the front of the furnace and enters the passage p. The heated air
conveyed by the pipe q (or in any other convenient manner) to the back
of the furnace rises up the vertical channel r, passes along the horizontal
channel 8, and is delivered into the passage t. The passages p and t
into which the gaseous fuel and heated air are respectively delivered
open into each other over the wall u, and the said gaseous fuel and
heated air there mingling produce on being ignited a powerful flame
which plays under the reverberating arch w of the furnace and effects
the heating of the said furnace and the materials contained therein.
The gaseous fuel as well as the atmospheric air are heated by passing
along the horizontal flues o and 8 in the sides (or top or bottom) of the
furnace.
It will be seen by reference to Figure 4 that the point at which the
gaseous fuel and atmospheric air mingle and burn is situated just above
the ground level of the gas furnace or producer, and I prefer in all
cases to have the point of ignition in the smelting or other furnace at
or above the level of the top of the gas furnace or producer. The
heated air and products of combustion pass from the arch w and bed
of the furnace down two vertical channels y, y, into the pit z. Any
easily condensed vapours passing from the furnace will be reduced to a
solid form and be deposited in the pit z, while the uncondensed gases
and vapours pass along the channel 2. In this channel 2 peroxide of
iron or other oxide of iron, baryta, or other absorbent material proper
to absorb the arsenical or sulphurous or other compounds given off

page_text: during the operation of the furnace are placed, the said absorvent
materials being spread on the bottom of the said channel 2. The
uncondensed vapours pass from the channel 2 to the condensing towers
represented in vertical section in Figure 7, the said vapours entering the
towers by conduits 3.
The apparatus, Figure 7, consists of two towers 4, 5. In the wells
or lower parts of the said towers water is put, and a series of trays
supporting oxide of iron, baryta, or other absorbent material are fixed
horizontally in the said towers. The said trays of absorbent materials
are marked 6 in the tower 4, and marked 7 in the tower 5. The
absorbent materials on the trays 6, 7, may be employed dry or may
be moistened by fine jets of water as may be required. As the vapour
passes from the conduit 3 over the water in the tower 4 and rises
through the absorbent materials on the trays 6, such portions of the
said vapours as are condensible by water, or the absorbent materials
are condensed, the remaining portion passing along the conduit 8
descends through the trays of absorbent materials 7, 7, in the tower 5
and over the water in the said tower 5. A further condensation thereby
takes place, the uncondensed gases and vapours passing out of the
apparatus, Figure 7, by the conduit 10. The gases and vapour passing
out by the conduit 10 are conveyed to the ordinary sulphuric acid
chambers, where they are used in the ordinary manner in the manu-
facture of sulphuric acid. By treating the gases passing from copper
smelting or other furnaces in the way described they are deprived of
all destructive or offensive matter, and do not contaminate the air of
the neighbourhood in which the said furnaces are used.
In order to control the passage of the gases and vapours through the
furnace and the condensing towers fans for producing any required
draught may be employed. I do not limit myself to any particular
position of the said fans, but I prefer to place one between the producer
or still and the furnace at the point marked 11 in Figure 4, and also
another at the end of the conduit 2 between the furnace and the towers,.
Figure 7, at the point marked 12 in Figure 5.
When I introduce nitrous acid gas, or oxygen, or other artificially
produced gas into the copper smelting or other furnace, Figures 4, 5,
and 6, I prefer to deliver the said gas through a small opening or
channel marked 13 in Figure 4; that is to say, I prefer to deliver the

page_text: said gas into the said furnace at or about the point where the gaseous
fuel and atmospheric air come into contact and burn.
Although I have described only one producer or still, yet several of the
said producers or stills may be arranged to work in conjunction, the said
producers or stills being placed side by side or arranged in any other
convenient manner, the air supplied to the furnace being heated by
being passed around the sides and back of the fire-places of the said
producers or stills, in the manner described with reference to the
producer or still Figures 1, 2, and 3. The atmospheric air may be
supplied to the smelting or other furnace cold when required. In this
case it is supplied directly from the atmosphere to the furnace without
passing through the heating conduits herein-before described.
When I employ illuminating gas or the gas obtained from oils or
fats, or substances other than coal, I make such changes in the gas
furnace or producer a, Figures 1, 2, and 3, as are necessary for the
producing of gas from the said substances. As the arrangements of
apparatus for these purposes are well known and constitute no part
of my Invention I do not think it necessary further to describe or
represent the same.
Although I have only described and represented my Invention as
applied to a furnace of the kind commonly called a copper smelting
furnace, yet my said Invention is applicable to other furnaces used
in the manufacture of copper, such as calcining, roasting, and refining,
and to furnaces used in the manufacture of other metals and for other
purposes.
In applying my Invention to kilns for burning or glazing earthenware,
bricks, tiles, pipes, and for other like purposes I prefer to arrange the
said kilns in a circular form and introduce the gaseous fuel and
atmospheric air into each of the said kilns in the manner described and
illustrated in Figures 4 and 5.
Having now described the nature of my Invention, and the manner
in which the same is to be performed, I wish it to be understood that I
do not limit myself to the precise details herein described and illustrated,
as the same may be varied without departing from the nature of my
Invention; but I claim as my Invention,-
Firstly. The improvements in smelting copper or other metals herein-
before described with reference to the accompanying Drawing, that is to

page_text: say, by means of gaseous fuel and atmospheric air with or without
artificially produced gases, the said gaseous fuel or atmospheric air or
both being heated (after the furnace has been in operation a short time)
on their way to that part of the furnace where they are ignited.
Secondly. The improvements in furnaces for smelting copper and
other metals and for other purposes herein-before described and illus-
trated in the accompanying Drawing, that is to say, the several
arrangements or combinations of the parts of furnaces for producing
and burning gaseous fuel in combination with atmospheric air and
with or without the admixture of other gases, and for heating the said
gaseous fuel and air, substantially as described and illustrated.
Thirdly. The improvements in obtaining products from the gases and
vapours given off during the smelting of copper and other metals,
herein-before described and illustrated in the accompanying Drawing,
that is to say, the arrangement of the parts of condensers to be used
for that purpose, substantially in the manner described and illustrated.
In witness whereof, I, the said Henry Causer Ensell, have here-
unto set my hand and seal, this Tenth day of February, in
the year of our Lord One thousand eight hundred and sixty-
nine.
Witness,
W. J. THOMSON,
St. Helen's,
Lancashire.
HENRY CAUSER ENSELL. (L.S.).
10