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See also:COPPER (See also:symbol Cu, atomic See also:weight 63.1, H=1, or 63.6, O = 16) , a See also:metal which has been known to and used by the human See also:race from the most remote periods . Its alloy with See also:tin (See also:bronze) was the first metallic See also:compound in See also:common use by mankind, and so extensive and characteristic was its employment in pre-historic times that the See also:epoch is known as the Bronze See also:Age . By the Greeks and See also:Romans both the metal and its See also:alloys were indifferently known as xaAicbr and aes . As, according to See also:Pliny, the See also:Roman See also:supply was chiefly See also:drawn from See also:Cyprus, it came to be termed aes cyprium, which was gradually shortened to cyprium, . and corrupted into cuprum, whence comes the See also:English word See also:copper, the See also:French cuivre, and the See also:German Kupfer . Copper is a brilliant metal of a See also:peculiar red See also:colour which assumes a pinkish or yellowish tinge on a freshly fractured See also:surface of the pure metal, and is purplish when the metal contains cuprous See also:oxide . Its specific gravity varies between 8.91 and 8.95, according to the treatment to which it may have been subjected; J . F . W . Hampe gives 8.945 (1o) for perfectly pure and compact copper . See also:Ordinary commercial copper is somewhat porous and has a specific gravity ranging from 8.2 to 8.5 . It takes a brilliant See also:polish, is in a high degree malleable and ductile, and in tenacity it only falls See also:short of See also:iron, exceeding in that quality both See also:silver and See also:gold . By different authorities its melting-point is stated at from l000° to 1200° C.; C . T . Heycock and F . H . See also:Neville give 1o8o •5; P . Dejean gives 1085° as the freezing-point . The molten metal is See also:sea-See also:green in colour, and at higher temperatures (in the electric arc) it vaporizes and See also:burns with a green See also:flame . G . W . A . Kahlbaum succeeded in subliming the metal in a vacuum, and H . See also:Moissan (Compt. rend., 1905, 141, p . 853) distilled it in the electric See also:furnace . Molten copper absorbs See also:carbon monoxide, See also:hydrogen and See also:sulphur dioxide; it also appears to decompose See also:hydrocarbons (methane, ethane), absorbing the hydrogen and the carbon separating out . These occluded gases are all liberated when the copper cools, and so give rise to porous castings, unless See also:special precautions are taken . The gases are also expelled from the molten metal by See also:lead, carbon dioxide, or See also:water vapour . Its specific See also:heat is o•o899 at o° C. and 0•0942 at See also:Ioo°; the coefficient of linear expansion per I° C. is o•oo1869 . In electric conductivity it stands next to silver; the conducting See also:power of silver being equal to Too, that of perfectly pure copper is given by A . Matthiessen as 96.4 at 13° C . Copper is not affected by exposure in dry See also:air, but in a moist See also:atmosphere, containing carbonic See also:acid, it becomes coated with a green basic carbonate . When heated or rubbed it emits a peculiar disagreeable odour . Sulphuric and hydrochloric acids have little or no See also:action upon it at ordinary temperatures, even when in a See also:fine See also:state of See also:division; but on See also:heating, copper sulphate and sulphur dioxide are formed in the first See also:case, and cuprous chloride and hydrogen in the second . Concentrated nitric acid has also very little action, but with the dilute acid a vigorous action ensues . The first products of this reaction are copper nitrate and nitric oxide, but, as the concentration of the copper nitrate increases, nitrous oxide and, eventually, See also:free See also:nitrogen are liberated . Many colloidal solutions of copper have been obtained .
A reddish-See also: It is not infrequently found in See also:serpentine, and in basic eruptive rocks, where it occurs as See also:veins and in amygdales . The largest known deposits are those in the See also:Lake See also:Superior region, near Keweenaw Point, See also:Michigan, where masses upwards of 400 tons in See also:weight have been discovered . The metal was formerly worked by the See also:Indians for implements and ornaments . It occurs in a See also:series of amygdaloidal dolerites or diabases, and in the associated sandstones and conglomerates . Native silver occurs with the copper, in some cases embedded in it, like crystals in a See also:porphyry . The copper is also accompanied by See also:epidote, See also:calcite, See also:prehnite, See also:analcite and other zeolitic minerals . Pseudomorphs after calcite are known; and it is notable that native copper occurs pseudomorphous after See also:aragonite at Corocoro, in See also:Bolivia, where the copper is disseminated through See also:sandstone . Ores.—The See also:principal ores of copper are the oxides See also:cuprite and See also:melaconite, the See also:carbonates See also:malachite and chessylite, the basic chloride See also:atacamite, the silicate See also:chrysocolla, the sulphides chalcocite, chalcopyrite, See also:erubescite and See also:tetrahedrite . Cuprite (q.v.) occurs in most cupriferous mines, but never by itself in large quantities . Melaconite (q.v.) was formerly largely worked in the Lake Superior region, and is abundant in some of the mines of See also:Tennessee and the See also:Mississippi valley . Malachite is a valuable ore containing about 56% of the metal; it is obtained in very large quantities from See also:South See also:Australia, See also:Siberia and other localities . Frequently intermixed with the green malachite is the See also:blue carbonate chessylite or See also:azurite (q.v.), an ore containing when pure 55'16% of the metal . Atacamite (q.v.) occurs chiefly in See also:Chile and See also:Peru . Chrysocolla (q.v.) contains in the pure state 30% of the metal; it is an abundant ore in Chile, See also:Wisconsin and See also:Missouri . The sulphur compounds of copper are, however, the most valuable from the economic point of view . Chalcocite, redruthite, copper-glance (q.v.) or vitreous copper (Cu2S) contains about 8o % of copper . Copper See also:pyrites, or chalcopyrite, contains 34.6% of copper when pure; but many of the ores, such as those worked specially by wet processes on See also:account of the presence of a large proportion of iron sulphide, contain less than 5% of copper . Cornish ores are almost entirely pyritic; and indeed it is from such ores that by far the largest proportion of copper is extracted throughout the See also:world . In See also:Cornwall copper lodes usually run See also:east and See also:west . They occur both in the " killas " or See also:clay-See also:slate, and in the " growan " or See also:granite . Erubescite (q.v.), bornite, or horseflesh ore is much richer in copper than the ordinary pyrites, and contains 56 or 57% of copper . Tetrahedrite (q.v.), fahlerz, or See also:grey copper, contains from 30 to 48% of copper, with See also:arsenic, See also:antimony, iron and sometimes See also:zinc, silver or See also:mercury . Other copper minerals are percylite (PbCuC12(OH)2), boleite (3PbCuC12(OH)2, AgC1), stromeyerite ((Cu, Ag)2S}, cubanite (CuS, Fe2S3), See also:stannite (Cu2S, FeSnS3), tennantite'(3Cu2S, As2S3), emplectite (Cu2S, Bi2S3), wolfsbergite (Cu2S, Sb2S3), famatinite (3Cu2S, Sb2S5) and enargite (3Cu2S, As2S5) . For other minerals, see Compounds of Copper below .
Metallurgy.—Copper is obtained from its ores by three principal methods, which may be denominated—(r) the pyro-metallurgical or dry method, (2) the hydro-metallurgical or wet method, and (3) the electro-metallurgical method
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The methods of working vary according to the nature of the ores treated and See also:local circumstances
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The dry method, or ordinary smelting, cannot be profitably practised with ores containing less than 4% of copper, for which and for still poorer ores the wet See also:process is preferred
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Copper Smelting.—We shall first give the See also:general principles which underlie the methods for the dry extraction of copper, and then proceed to a more detailed discussion of the plant used
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Since all sulphuretted copper ores (and these are of the most economic importance) are invariably contaminated with arsenic and antimony, it is necessary to eliminate these impurities, as far as possible, at a very See also:early See also:stage
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This is effected by calcination or roasting
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The roasted ore is then smelted to a mixture of copper and iron sulphides, known as copper " matte " or " coarse-metal," which contains little or no arsenic, antimony or See also:silica
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The coarse-metal is now smelted, with See also:coke and siliceous fluxes (in See also:order to slag off the irqn), and the product, consisting of an impure copper sulphide, is variously known as
blue-metal," when more or less iron is still See also:present, " pimple-metal," when free copper and more or less copper oxide is present, or " fine " or " See also: The plant in which the operations are conducted varies in different countries . But though this or that process takes its name from the See also:country in which it has been mainly See also:developed, this does not mean that only that process is there followed . The " English process " is made up of the following operations: (r) calcination; (2) smelting in reverberatory furnaces to form the matte; (3) roasting the matte; and (4) subsequent smelting in reverberatory furnaces to fine- or white-metal; (5) treating the fine-metal in reverberatory furnaces to coarse- or See also:blister-copper, either with or without previous calcination; (6) refining of the coarse-copper . A shorter process (the so-called " direct process ") converts the fine-metal into refined copper directly . The " Welsh process " closely resembles the English method; the See also:main difference consists in the enrichment of the matte by smelting with the See also:rich copper-bearing slags obtained in subsequent operations . The " German or Swedish process " is characterized by the introduction of blast-furnaces . It is made up of the following operations: (I) calcination, (2) smelting in blast-furnaces to form the matte, (3) roasting the matte, (4) smelting in blast-furnaces with coke and fluxes to " See also:black- " or " coarse-metal," (5) refining the coarse-metal . The " Anglo-German Process " is a See also:combination of the two preceding, and consists in smelting the calcined ores in See also:shaft furnaces, concentrating the matte in reverberatory furnaces, and smelting to coarse-metal in either . The impurities contained in coarse-copper are mainly iron, lead, zinc, See also:cobalt, See also:nickel, See also:bismuth, arsenic, antimony, sulphur, See also:selenium and See also:tellurium . These can be eliminated by an oxidizing See also:fusion, and slagging or volatilizing the products resulting from this operation, or by See also:electrolysis (see below) . In the process of oxidation, a certain amount of cuprous oxide is always formed, which melts in with the copper and diminishes its softness and tenacity . It is, therefore, necessary to reconvert the oxide into the metal . This is effected by stirring the molten metal with a See also:pole of green See also:wood (" poling "); the products which arise from the See also:combustion and See also:distillation of the wood reduce the oxide to metal, and if the operation be properly conducted " tough-See also:pitch " copper, soft, malleable and exhibiting a lustrous silky fracture, is obtained . The surface of the molten metal is protected from oxidation by a layer of See also:anthracite or See also:charcoal . ".See also:Bean-shot " eopper is obtained by throwing the molten metal into hot water; if See also:cold water be used, " feathered-shot " copper is formed . " Rosette " copper is obtained as thin plates of a characteristic dark-red colour, by pouring water upon the surface of the molten metal, and removing the crust formed . " See also:Japan " copper is See also:purple-red in colour, and is formed by casting into ingots, weighing from six ounces to a See also:pound, and rapidly cooling by See also:immersion in water . The colour of these two varieties is due to a layer of oxide . " See also:Tile " copper is an impure copper, and is obtained by refining the first tappings . " Best-selected " copper is a purer variety . Calcination or Roasting and Calcining Furnaces.—The roasting should be conducted so as to eliminate as much of the arsenic and antimony as possible, and to leave just enough sulphur as is necessary to combine with all the copper present when the calcined ore is smelted . The process is effected either in heaps, stalls, shaft furnaces, reverberatory furnaces or muffle furnaces . See also:Stall and heap roasting require considerable See also:time, and can only be economically employed when the loss of the sulphur is of no consequence; they also occupy much space, but they have the See also:advantage of requiring little See also:fuel and handling . Shaft furnaces are in use for ores rich in sulphur, and where it is desirable to convert the See also:waste gases into sulphuric acid . Reverberatory roasting does not admit of the utilization of the waste gases, and requires fine ores and much labour and fuel; it has, however, the advantage of being rapid . Muffle furnaces are suitable for fine ores which are liable to decrepitate or See also:sinter . They involve high cost in fuel and labour, but permit the utilization of the waste gases . Reverberatory furnaces of three types are employed in calcining copper ores: (i) fixed furnaces, with either See also:hand or See also:mechanical rabbling; (2) furnaces with movable beds; (3) furnaces with rotating working See also:chambers . Hand rabbling in fixed furnaces has been largely superseded by mechanical rabbling . Of mechanically rabbling furnaces we may mention the O'Harra modified by See also:Allen-Brown, the Hixon, the See also:Keller-Gaylord-See also:Cole, the Ropp, the See also:Spence, the Wethey, the See also:Parkes, See also:Pearce's " See also:Turret " and Brown's " Horseshoe " furnaces . See also:Blake's and See also:Brunton's furnaces are reverberatory furnaces with a movable See also:bed . Furnaces with rotating working chambers admit of continuous working; the fuel and labour See also:costs are both See also:low . In the White-See also:Howell revolving furnace with lifters—a modification of the Oxland—the ore is fed and discharged in a continuous stream . The See also:Bruckner See also:cylinder resembles the Elliot and See also:Russell black ash furnace; its cylinder tapers slightly towards each end, and is generally i8 ft. See also:long by 8 ft . 6 in. in its greatest See also:diameter . Its See also:charge of from 8 to 12 tons of ore or concentrates is slowly agitated at a See also:rate of three revolutions a See also:minute, and in from 24 to 36 See also:hours it is reduced from say 40 or 35 % to 7 % of sulphur . The ore is under better See also:control than is possible with the continuous feed and See also:discharge, and when sufficiently roasted can be passed red-hot to the reverberatory furnace . These advantages compensate for the See also:wear and See also:tear and the cost of moving the heavy dead-weight . Shaft calcining furnaces are available for fine ores and permit the recovery of the sulphur . They are square, oblong or circular in See also:section, and the interior is fitted with See also:horizontal or inclined plates or prisms, which regulate the fall of the ore . In the Gerstenhoffer and Hasenclever-Helbig furnaces the fall is retarded by prisms and inclined plates . In other furnaces the ore rests on a series of horizontal plates, and either remains on the same See also:plate throughout the operation (011ivier and Perret furnace), or is passed from plate to plate by hand (Maletra), or by mechanical means (Spence and M'Dougall) . The M'Dougall furnace is turret-shaped, and consists of a series of circular hearths, on which the ore is agitated by rakes attached to revolving arms and made to fall from See also:hearth to hearth . It has been modified by Herreshoff, who uses a large hollow revolving central shaft cooled by a current of air . The shaft is provided with sockets, into which movable arms with their rakes are readily dropped . The See also:Peter Spence type of calcining furnace has been followed in a large number of inventions . In some the rakes are attached to rigid frames, with a reciprocating See also:motion; in others to See also:cross-bars moved by revolving chains . Some ofthese furnaces are straight, others circular . Some have only one hearth, others three . This and the previous type of furnace, owing to their large capacity, are at present in greatest favour . The M'Dougall-Herreshoff, working on ores of over 30% of sulphur, requires no fuel; but in furnaces of the reverberatory type fuel must be used, as an excess of air enters through the slotted sides and the hinged doors which open and shut frequently to permit of the passage of the rakes . The See also:consumption of fuel, however, does not exceed r of See also:coal to ro of ore . The quantity of ore which these large furnaces, with a hearth See also:area as See also:great as 2000 ft. and over, will roast varies from 40 to 6o tons a See also:day . Shaft calcining furnaces like the Gerstenhoffer, Hasenclever, and others designed for burning pyrites fines have not found favour in See also:modern copper See also:works . The Fusion of Ores in Reverberatory and See also:Cupola Furnaces.—After the ore has been partially calcined, it is smelted to See also:extract its earthy matter and to concentrate the copper with See also:part of its iron and sulphur into a matte . In reverberatory furnaces it is smelted by fuel in a fireplace, See also:separate from the ore, and in cupolas the fuel, generally coke, is in direct contact with the ore . When See also:Swansea was the centre of the copper-smelting See also:industry in See also:Europe, many varieties of ores from different mines were smelted in the same furnaces, and the Welsh reverberatory furnaces were used . To-day more than eight-tenths of the copper ores of the world are reduced to impure copper bars or to fine copper at the mines; and where the See also:character of the ore permits, the cupola furnace is found more economical in both fuel and labour than the reverberatory . The Welsh method finds adherents only in See also:Wales and Chile . In See also:America the usual method is to roast ores or concentrates so that the matte yielded by either the reverberatory or cupola furnace will run from 45 to 50% in copper, and then to See also:transfer to the Bessemer converter, which blows it up to 99 % . In See also:Butte, See also:Montana, reverberatories have in the past been preferred to cupola furnaces, as the charge has consisted mainly of fine roasted concentrates; but the cupola is gaining ground there . At the See also:Boston and Great Falls (Montana) works tilting reverberatories, modelled after open hearth See also:steel furnaces, were first erected; but they were found to possess objectionable features . Now both these and the See also:egg-shaped reverberatories are being abandoned for furnaces as long as 43 ft . 6 in. from See also:bridge to bridge and of a width of 15 ft . 9 in. heated by See also:gas, with re-generative checker See also:work at each end, and fed with ore or See also:con, centrates, red-hot from the calciners, through a See also:line of hoppers suspended above the roof . Furnaces of this See also:size See also:smelt 200 tons of charge a day . But even when the old type of reverberatory is preferred, as at the Argo works, at See also:Denver, where rich gold. and silver-bearing copper matte is made, the growth of the furnace in size has been steady . See also:Richard Pearce's reverberatories in 1878 had an area of hearth of 15 ft. by 9 ft . 8 in., and smelted 12 tons of cold charge daily, with a consumption of i ton of coal to 2.4 tons of ore . In r900 the furnaces were 35 ft. by 16 ft., and smelt 5o tons daily of hot ore, with the consumption of i ton of coal to 3.7 tons of ore . The See also:home of cupola smelting was See also:Germany, where it has never ceased to make steady progress . In See also:Mansfeld See also:brick cupola furnaces are without a See also:rival in size, equipment and performance . They are See also:round stacks, designed on the See also:model of iron blast furnaces, 29 ft. high, fed mechanically, and provided with stoves to heat the blast by the furnace gases . The low percentage of sulphur in the roasted ore is little more than enough to produce a matte of 40 to 45%, and therefore the escaping gases are better fitted than those of most copper cupola furnaces for burning in a See also:stove . But as the slag carries on an See also:average 46 % of silica, it is only through the utmost skill that it can be made to run as low on an average as o•3 % in copper oxide . As the matte contains on an average o•2% of silver, it is still treated by the Ziervogel wet method of extraction, the management dreading the loss which might occur in the Bessemer process of concentration, applied as preliminary to electrolytic separation . Blast furnaces of large size, built of brick, have been constructed for treating the richest aDd more silicious ores of Rio Tinto, and the Rio Tinto See also:Company has introduced converters at the mine . This method of extraction contrasts favourably in time with the leaching process, which is so slow that over ro,000,000 tons of ore are always under treatment on the immense leaching floors of the company's works in See also:Spain . In the See also:United States the cupola has undergone a See also:radical modification in being built of water-jacketed sections . The first water-jacketed cupola which came into general use was a circular inverted See also:cone, with a slight See also:taper, of 36 inches diameter at the tuyeres, and composed of an See also:outer and an inner metal See also:shell, between which water circulated . As greater size has been demanded, See also:oval and rectangular furnaces—as large as 18o in. by 56 in. at the tuyereshave been built in sections of See also:cast or See also:sheet iron or steel . A single section can be removed and replaced without entirely emptying the stack, as a shell of congealed slag always coats the inner surface of the jacket . The largest furnaces are those of the Boston & Montana Company at Great Falls, Montana, which have put through 500 tons of charge daily, pouring their melted slag and matte into large See also:wells of ro ft. in diameter . A combined brick- and water-cooled furnace has been adopted by the Iron See also:Mountain Company at See also:Keswick, Cal., for matte concentration .
In it the cooling is effected by water pipes, interposed horizontally between the layers of bricks
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The Mt
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See also:Lyell smelting works in See also:Tasmania, which are of special See also:interest, will be referred to later
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(See Pyritic Smelting below.)
Concentrating Matte to Copper in the Bessemer Converter.—As soon as the pneumatic method of decarburizing See also:pig iron was accepted as practicable, experiments were made with a view to Bessemerizing copper ores and mattes
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One of the earliest and most exhaustive series of experiments was made on Rio Tinto ores at the See also: Vessels of several designs are used—some modelled exactly after steel converters, other See also:barrel-shaped, but all with side tuyeres elevated about so in. above the level of the bottom lining . Practice, however, in treating copper matte differs essentially from the treatment of pig iron, inasmuch as from 20 to 30% of iron must be eliminated as slag and an See also:equivalent quantity of silica must be supplied . The only See also:practical mode of doing this, as yet devised, is by lining the converter with a silicious mixture . This is so rapidly consumed that the converters must be cooled and partially relined after 3 to 6 charges, dependent on the iron contents of the matte . When available, a silicious rock containing copper or the See also:precious metals is of course preferred to barren lining . The material for lining, and the frequent replacement thereof, constitute the principal expense of the method . The other items of cost are labour, the quantity of which depends on the mechanical appliances provided for handling the converter shells and inserting the lining; and the blast, which in barrel-shaped converters is low and in See also:vertical converters is high, and which varies therefore from 3 to 15 lb to the square See also:inch . The quantity of air consumed in a converter which will See also:blow up about 35 tons of matte per day is about 3000 cub. ft. per minute . The operation of raising a charge of 50% matte to copper usually consists of two blows . The first blow occupies about 25 minutes, and oxidizes all but a small quantity of the iron and some of the sulphur, raisingthe product to white metal . The slag is then poured and skimmed, the blast turned on and converter retilted . During the second blow the sulphur is rapidly oxidized, and the charge reduced to metal of 99% in from 30 to 40 minutes . Little or no slag results from the second blow . That from the first blow contains between 1% and 2% of copper, and is usually poured from ladles operated by an electric See also:crane into a reverberatory, or into the settling well of the cupola . The matte also, in all economically planned works, is conveyed, still molten, by electric See also:cranes from the furnace to the converters . When lead or zinc is not present in notable quantity, the loss of the precious metals by volatilization is slight, but more than 5% of these metals in the matte is prohibitive . Under favourable conditions in the larger works of the United States the cost of converting a 50% matte to metallic copper is generally understood to be only about 15w to 3- of a cent per lb. of refined copper . Pyritic Smelting.—The heat generated by the oxidation of iron and sulphur has always been used to maintain combustion in the kilns or stalls for roasting pyrites . Pyritic smelting is a development of the See also:Russian engineer Semenikov's treatment (proposed in 1866) of copper matte in a Bessemer converter . Since John Hollway's and other early experiments of See also: |