Improvements in and relating to the Smelting of Ores and Refining of Metals, and to Apparatus therefor.
Year: 1893

page_text: Date of Application, 25th Apr., 1893-Accepted, 1st July, 1893
COMPLETE SPECIFICATION.
Improvements in and relating to the Smelting of Ores and Refining
of Metals, and to Apparatus therefor.
I, CHARLES MAURICE ALLEN, Mining Engineer, residing at 643 Talbot Avenue,
Butte City, in the County of Silver Bow and State of Montana, United States of
America, do hereby declare the nature of my invention, and in what manner the
same is to be performed, to be particularly described in and by the following
statement:—
The object of my invention is to provide for smelting ores and refining metals in
one operation, and for utilizing as fuel the sulphur in the ores to be refined or
smelted; and the invention consists in the process and in the combination, arrange-
ment, and operation of the features hereinafter described and claimed.
In the accompanying drawings,
Figure 1 is a vertical sectional elevation;
Fig. 2 a cross section taken on line 2 of Fig. 1;
Fig. 3 an enlarged sectional view of one of the tuyers;
Fig. 4 a sectional view of the plug used for closing the tuyers;
Fig. 5 a longitudinal sectional view of one of my improved tuyers;
Fig. 6 a sectional view, taken on line 6 of Fig. 5;
Fig. 7 a vertical sectional elevation of the lower portion of a modified arrangement
of the convertor ;
Fig. 8 a cross section through the bottom on line 8 of Fig. 7;
Fig. 9 a broken side elevation of the top of one of the overflow pipes; and
Fig. 10 a section showing the top and sides of the bottom jacket formed of one
continuous plate.
In carrying out my process, I use a combined convertor, A, and blast furnace, B,
which, as shown, is circular in form, but which may be square, oval, rectangular,
or in any shape desired. The convertor, which is stationary, is immediately under
the blast furnace, the two thus practically forming one structure or machine, which
rests upon any suitable base or support. The sides of the furnace and convertor
are preferably made of steel, iron, or copper plates, with an intervening water space,
as in the usual form of water jacket furnaces, the bottom being also water jacketed.
The sides extending down continuously form a chamber in the lower portion, which
corresponds to the gradual continuous taper of the furnace, and, as just suggested,
I prefer to have the water jacket extend down and under this chamber, so as to form
both the sides and bottom thereof. The water jacketed sides and bottom of the
furnace coming into direct contact with the charge, the use of linings is rendered
unnecessary. There are two rows of tuyers, a and b, one above the other, the upper
row being for the blast furnace and the lower row for the convertor.
The tuyers
enter the chamber preferably at right angles to a perpendicular line drawn in the
furnace, but this is not in all cases necessary. The raw sulphides, ore, matte, or
other substances to be treated, are introduced through a suitable opening in the top
or sides, as may be most convenient. The top of the furnace may be so shaped that
the particles thrown upwards by the force of the blast will strike against a covering,
preferably water jacketed, after which they will be conducted along with the fumes
and gases into dust chambers or flues, where they will be deposited, the fumes and
gases passing thence through a stack or chimney to the outer air. Of course, the
lower tuyers should be closed whenever it is desired not to convert, and the upper
tuyers closed whenever it is desired to convert. For this purpose, I employ suitable
plugs, D, made of the material to be treated, clay or other material. I prefer to
make these plugs so that they may be driven in to open the tuyers, and also to make
them of the same material as that treated in the convertor, so that when driven in
LD

page_text: there will be no loss or introduction of foreign matter into the charge. I also
prefer to provide the convertor with a suitable slag tap, b', at a point higher than
the metal tap a', to permit the slag to be drawn off as desired. This slag tap is
applicable to any form of convertor, and, therefore, it will be understood that I do
not intend to limit myself to its use in a combined convertor and blast furnace, or
in any particular form of convertor-the novel feature in this respect consisting in
providing a convertor with a slag tap, such taps having been heretofore used in blast
furnaces only.
In Figs. 5 and 6, I have shown certain improvements in tuyers, which I prefer
to use in connection with a convertor, although they are applicable to either
a blast furnace or convertor. It will be understood, therefore, that when I use
'the term <6 convertor in describing my improvements in tuyers, I use it in a
general sense, and as meaning either a blast furnace or convertor, as circumstances
may require.
As convertors are now constructed, there is no way of stopping the blast,
except by tipping the convertor, and at the same time preventing the molten
material from running into the tuyer. Owing to this, there is no way of shutting
off the blast and stopping agitation, so as to permit slag, matte and metal to
be separated in the furnace. The object of the improvements I am now describing
is to obviate this difficulty and provide convenient means for allowing separation in
the furnace.
In constructing my improved tuyers, I provide for introducing the plugs, D,
preferably of the material reduced in the convertor to close the tuyer whenever it
is desired to stop the blast. The plugs are introduced into the tuyer through a
pipe connecting with a magazine, E, adapted to hold any number desired. As
shown, this magazine is above the tuyer, and is provided with a sliding top e and
bottom e', which I call valved openings-the top sliding only when it is desired to
insert plugs, and the bottom only when it is desired to introduce one into the
tuyer. As shown, the sliding top and bottom are metallic plates adapted to move
back and forth in horizontal grooves in the walls of the magazine, but they may
be made of other material and in other forms, the only essential in this respect
being that they be capable of properly admitting the plugs into the magazine and
allowing them to drop therefrom, as desired. The magazine being filled with plugs,
when it is desired to introduce one into the tuyer, the sliding bottom is drawn back
to permit one of the plugs to drop down, the others being held in position in any
convenient way.
When the sliding bottom is opened, the lowest plug drops on to
a suitable support or trough in a pipe connected with the tuyer, and in such
position that it is immediately forced forward by the blast into the opening of the
tuyer, the plug having an enlargement on its outer end to prevent its being
blown through the tuyer into the convertor. When forced into the opening
of the tuyer by the blast, the plug immediately closes the tuyer, and thus shuts off
the blast and at the same time prevents the molten material from running into
the tuyer.
In order to open the tuyer again, I provide for driving in or drawing out the
plug by means of a rod or screw, or otherwise. The rod or screw, when one is used,
may be made to hold the plug in place, so as to prevent its being forced out by
internal pressure whenever it is desired to stop or remove the force of the blast.
Of course, the portion of the rod or screw, intended to pass through the opening
of the tuyer, should be so constructed that when driven in it will not in itself
close the opening. In other words, it should be so constructed as to permit the
entrance of sufficient blast to keep the molten material from running into the
tuyer.
Although I prefer to make the plugs of the material intended to be reduced in
the convertor, still I contemplate forming them of metal, or of any other suitable
material, and of course they should be of the size or shape necessary for the tuyer
in which they are to be used. Although I have shown the magazine for holding
the plugs in a position higher than the tuyer, so as to permit the plugs to drop

page_text: down, I also contemplate placing it in any convenient position-in some cases, it
may be found advisable to place it at the side or below the tuyer, proper means
being employed to force the plug into position in the tuyer. I also contemplate
using other means than a rod or screw for forcing in or drawing out the plug-as,
for instance, an ordinary bar, or a bar and lever. In short, as the essence of my
invention, now being described, consists in providing for shutting off the blast and
at the same time preventing molten material from running into the tuyer, I do not
intend to limit myself to minor features or details of construction.
In Figs. 7 to 10, inclusive, I have shown certain modifications in the construction
and arrangement of the bottom of the convertor, which are not illustrated in Fig. 1.
In making my improved blast furnace or convertor, shown in Fig. 7, I make a
bottom water jacket, F, of a size and shape to be inserted from below, and to be
surrounded by the lower edges of the side water jackets. By this arrangement,
there will be avoided the burning of the side jackets near the bottom, which is
liable to occur when they rest upon the bottom jacket, as shown in Fig. 1, owing to
sediment from the water settling in the bottom to such an extent as to prevent
free circulation of the water at that point. The settlement of mud or sediment in
the bottom of the side jackets when extended below the upper surface of the
bottom, as in my arrangement, cannot have this effect.
In order to avoid making any holes in the upper plate of the bottom water
jacket, and still have it supported so that it will sustain the heavy weight to which
it is subjected in use, I arrange between the upper and lower plates of the bottom
jacket a number of thimbles or collars, G, which are held in position by rivets or
bolts, g, extending through the lower plate of the bottom. The collars are counter-
sunk at the upper ends to admit the head of the rivets or bolts, as shown in Fig. 8.
This enables the upper plate of the jacket to rest upon the thimbles and to be
sufficiently supported without making the holes through them, as has heretofore
been done. I further construct this jacket of two plates only, by so flanging the
edges of the upper plate that they will extend down forming the sides, and join the
lower plate, as shown in Fig. 4, which forms a jacket without a hole in either top
or sides, and thus renders it safe from leaking internally-that is to say, if any of
the joints open, they will leak outside of the furnace.
To supply the interior of the bottom jacket with water, I lead a pipe or pipes, H,
from any convenient water source, so that water may be admitted or flow in as
desired. To afford an outflow for the water, I arrange a pipe or pipes, I, whose
upper ends are extended to or near the upper plate of the bottom jacket, as shown
in Fig. 7. The upper edge of the overflow pipe is preferably notched or corrugated,
as shown in Fig. 9, so that when the water has filled the space between the upper
and lower plates of the bottom jacket, it may escape over such upper edge.
By arranging the upper end of the overflow pipe immediately below the upper
plate of the bottom jacket, 1 prevent the steam from keeping the water away from
the upper plate, inasmuch as it must rise to the upper plate in order to escape; and
the steam which forms in the upper portion of the space can also freely escape
through the overflow pipe, which it could not do if the pipe led from the bottom or
other lower point.
In carrying out my improved process, a wood fire is built in the bottom of the
convertor, after which coke is added until a good fire is burning above the tuyers.
A gentle blast is then turned on through the upper row of tuyers, the lower row being
closed with plugs of the material to be treated, or with clay or metal, the metal
tap held in place, and the slag tap closed with a suitable plug or stopper. After
the coke is all aglow, the raw sulphides are added and the blast increased, gradually
adding sulphides and coke until the molten mass reaches the upper tuyers. The
plugs in the lower tuyers being removed-if formed of the material to be treated
they may be simply driven in-and a blast of sufficient pressure, according to the
height of the charge, being turned on, the conversion of the sulphides to metals
will immediately begin, the oxygen and sulphur uniting with the air to form SO,,
which escapes through the stack. The iron in the ore, present as a sulphide,

page_text: which in this state refuses even in a plastic condition to unite with the silica (SiO2)
becomes an oxide (FeO) and unites with the silica to form a silicate of iron.
By regulating the proportion of the pyrites to silica or quartz, which can be
readily done by previous concentration with jigs and vanners or other concentrating
machinery, or if necessary by the addition to the charge of lime rock (CaCO₂)
any desired slag can be produced. As the presence of sulphides of iron always
reduces the oxides of copper, and as by the use of this continuous process fresh
raw sulphides are constantly added, this operation is peculiarly adapted to make
good clean slag. After the blowing has progressed sufficiently, the blast is stopped
or checked, and the material allowed to separate in the furnace, after which the
slag tap is opened with a pointed bar or otherwise, as in other forms of blast
furnace smelting, and a certain amount of slag allowed to run out, the amount
being determined by measurement in suitable vessels and approximated to the
weight of slag making material treated, which has been previously determined by
the metallurgist in charge. Of course, care should be taken not to remove all the
slag, a certain amount being necessary to arrest the oxides formed in the convertor
below. These oxides are arrested by coming in contact with the molten sulphides
on top of the metallic bath, or by passing through slag above the molten sulphides.
A certain amount of metal, say copper or lead, is now tapped out, during which
process an equal weight of sulphides is added to the charge from above. The
tuyers being reopened and the blast again turned on, the molten mass that remains
-being in a white heat-ignites the new charge immediately, and so the process
goes on continuously, the slag and metal being drawn off and ore added as in other
smelting processes.
In
Of course, a sufficient height of molten material to cover the tuyers must be
carried at all times during the operation of the furnace, and the blast must be
strong enough to prevent the molten material from entering the tuyers.
other words, the blast pressure must be greater during the smelting operation
than the weight of molten material above the tuyers. This strong blast necessarily
keeps the molten mass in constant agitation while the smelting operation is in
progress, but as soon as matte or metal of a desired grade is produced, the
blast must be stopped or checked by closing some or all of the tuyers, as above
mentioned, to the extent necessary to stop agitation. This stopping or checking
of the blast is an important step in my process, inasmuch as by stopping
agitation, it permits the different materials to separate in the furnace-say as
sand suspended in water by agitation settles when the agitation ceases-and
thus allows the slag to be drawn from one point, matte or metal from
another, &c. It also dispenses with the necessity of tipping the furnace to
raise the tuyers above the charge, when it is desired to accomplish separation.
It will thus be seen that I provide for continuously treating metals contained in
raw sulphide ores by smelting, converting and refining at one operation, and also
for using the sulphur contained in the metallic sulphides as fuel.
In this way, I
avoid the preliminary calcining or roasting of the sulphide ores and the subsequent
smelting to metallic matte, and also save much of the fuel necessary in smelting.
In other words, I am able by this process to smelt ore by a blast heated by passing
through molten material or matte, and also to smelt ore and convert the valuable
metals contained in raw sulphides into a metallic state-as, for instance, "black"
or "blister" copper in one operation, and without the use of any fuel, except that
necessary for starting and maintaining the blast. I am also able to dispense with
the stove usually employed in heating the blast required for pyritic smelting.
I am aware that attempts have been made to separate matte, metal and slag in a
convertor, by stopping the blast by the use of a movable tuyer adapted to be
dipped into the molten material or withdrawn therefrom; but this method has not
been found practicable, because of the rapid destruction of the tuyer, difficulty of
keeping it open, and the impossibility of introducing it through a charge of ore.
My process obviates all these objections, the tuyer being fixed and indestructible,
easily kept open, and capable of use under any charge or weight of ore. I therefore

page_text: disclaim any process in which the blast is checked or stopped by withdrawing
the tuyer from the charge, and limit myself to a process in which a stationary
tuyer is used and the stopping or checking of the blast effected by plugging.
I desire to say, in conclusion, that as the essence of my invention consists in the
process described, it will of course be understood that I do not intend to limit
myself to minor features or details of operation, or in every case to the accomplish-
ment of all the objects or benefits specified. Nor do I contemplate limiting the use of
my process to the treatment of any particular kind of ores; it being my intention to
use the same with any ores to which it may be applicable. Nor do I intend to
limit myself to the mechanical details and features described, further than as the
same may be specified in the claims.
Having now particularly described and ascertained the nature of my said
invention, and in what manner the same is performed, I declare that what I
claim is :-
1. The process of smelting ores, which consists in subjecting them to a blast
heated by passing through molten metal or matte in a furnace or converter, and
checking or stopping the blast by plugging the tuyers, to permit slag, matte and
metal to separate in the convertor, substantially as described.
2. The process of smelting ores and refining metals, which consists in melting
ores in a furnace or convertor, forcing a blast through the molten material, checking
or stopping the blast by plugging the tuyers, to permit slag, matte and metal to
separate in the convertor, and tapping the slag, matte and metal from the convertor
separately and at different heights, substantially as described.
3. The process of smelting ores and refining metals, which consists in feeding
raw sulphides into a furnace or convertor, subjecting them to a blast heated by
passing through molten material, checking or stopping the blast by plugging the
tuyers, to permit slag, matte and metal to separate in the convertor separately and
at different heights, and retaining sufficient molten material after each tap to ignite
the next charge, substantially as described.
4. In combination with an apparatus for treating ores or molten material and
provided with tuyers for the introduction of a blast, plugs for closing the tuyers
formed of the material to be treated and adapted to be driven in to open the tuyers,
substantially as described.
5. A tuyer for convertors or blast furnaces provided with a magazine for holding
plugs, and a trough or support for guiding plugs into the opening of the tuyer,
substantially as described.
6. A tuyer for convertors or blast furnaces provided with a magazine for holding
plugs, a trough or support for guiding plugs into the opening of the tuyer, and
means for holding the plug in the opening, the magazine being provided with valved
openings, substantially as described.
7. A tuyer for convertors or blast furnaces provided with a magazine for holding
plugs, a trough or support below the magazine for guiding plugs into the opening
in the tuyer, and a rod for holding the plug in the opening and driving it into the
convertor, the magazine being provided with valved openings, substantially as
described.
8. In combination with an apparatus for treating ores or molten material, a
bottom water jacket comprising an upper and a lower plate separated by thimbles
on the tops of which the upper plate rests, substantially as described.
9. In combination with an apparatus for treating ores or molten material, a
bottom water jacket comprising an upper and a lower plate, a water supply pipe for
admitting water into the space between the plates, and an overflow pipe extending
up to near the bottom of the upper plate for the exit of water and steam from
immediately below the upper plate, substantially as described.
10. In combination with an apparatus for treating ores or molten material, a
bottom water jacket comprising an upper and a lower plate, a water supply pipe
for admitting water into the space between the plates, and an overflow pipe

page_text: corrugated or notched at its upper end and extending up to near the bottom of the
upper plate for the exit of water and steam from immediately below the upper
plate, substantially as described.
11. In combination with an apparatus for treating ores or molten material, a
bottom water jacket inserted from below and to be surrounded by the lower edges 5
of the side water jackets, substantially as described.
Dated this 25th day of April 1893.
HASELTINE, LAKE & Co.,
45, Southampton Buildings, London, Agents for the Applicant.