COPPER is one of the metals most anciently known. It was named from the island of Cyprus, where it was extensively mined and smelted by the Greeks. It has a reddish brown colour inclining to yellow; a faint but nauseous and rather disagreeable taste; and when rubbed between the fingers it imparts a smell somewhat analogous to its taste. Its specific gravity is from 8·8 to 8·9. It is much more malleable than it is ductile; so that far finer leaves may be obtained from it than wire. It melts at the 27th degree of Wedgewood’s pyrometer, and at a higher temperature it evaporates in fumes which tinge the fire of a bluish green. By exposure to heat with access of air, it is rapidly converted into black scales of peroxide. In tenacity it yields to iron; but surpasses gold, silver, and platinum, considerably in this respect.In mineralogy, the genus copper includes about 13 different species, and each of these contains a great many varieties. These ores do not possess any one general exterior character by which they can be recognized; but they are readily distinguished by chemical re-agents. Water of ammonia digested upon any of the cupreous ores in a pulverized state, after they have been calcined either alone or with nitre, assumes an intense blue colour, indicative of copper. The richest of the ordinary ores appear under two aspects; the first class has a metallic lustre, a copper red, brass yellow, iron gray, or blackish gray colour, sometimes inclining to blue; the second is without metallic appearance, has a red colour, verging upon purple, blue, or green, the last tint being the most usual. Few copper ores are to be met with, indeed, which do not betray the presence of this metal by more or less of a greenish film.1.Native copper, occurs in crystals, branches and filaments, its most common locality being in primitive rocks. It is found abundantly in Siberia, at the mines of Tourinski, in those of Hungary, of Fundo-Moldavi in Gallicia, of Fahlun in Sweden,of Cornwall, &c. The gangues of native copper are granite, gneiss, mica-slate, clay-slate, quartz, carbonate or fluate of lime, sulphate of barytes, &c. The most remarkable masses of native copper hitherto observed were; first, one in Brazil, 14 leagues from Basa, which weighed 2616 pounds; and secondly, another which Dr. Francis-le-Baron discovered in America to the south of Lake Superior. It was nearly 15 feet in circumference.2.Sulphuret of Copper, the vitreous ore of Brochant.The texture of this ore is compact: its fracture, conchoidal, surface sometimes dull; colour, iron black or lead gray, often bluish, iridescent, or reddish from a mixture of protoxide. It is easily melted even by the heat of a candle; but more difficult of reduction than protoxide. This ore yields to the knife, assuming a metallic lustre when cut. Its density varies from 4·8 to 5·34. Its composition according to Klaproth is 78·5 copper, 18·5 sulphur, with a little iron and silica. Its equivalent constitution by theory is 80 copper + 20 sulphur = 100; whence 78·5 of metal should be associated with 19·6 of sulphur. This ore is therefore one of the richest ores, and forms very powerful veins, which likewise contain some orange protoxide. It is to be found in all considerable copper districts; in Siberia, Saxony, Sweden, and especially Cornwall, where the finest crystals occur.3.Copper Pyrites, resembles in its metallic yellow hue, sulphuret of iron; but the latter is less pale, harder, and strikes fire more easily with steel. It presents the most lively rainbow colours. Its specific gravity is 4·3. It contains generally a good deal of iron; as the following analysis will show; copper 30, sulphur 37, iron 33, in 100 parts. According to Hisinger, the Swedish pyrites contains 63 of copper, 12 of iron, and 25 of sulphur. These ores occur in primitive and transition districts in vast masses and powerful veins; and are commonly accompanied with gray copper, sulphuret of iron, sparry iron, sulphurets of lead, and zinc.4.Gray Copper, has a steel gray colour, more or less deep, either shining or dull; fracture uneven; a distinct metallic lustre; difficult of fusion at the blowpipe; it communicates to glass of borax a yellowish-red colour. Its density in crystals is 4·86. Its composition is very variable; consisting essentially of copper, iron, antimony, and sulphur. The exploration of this ore is profitable, in consequence of the silver which it frequently contains. It occurs in primitive mountains; and is often accompanied with red silver ore, copper pyrites, and crystallized quartz.5.Protoxide of Copper, orred oxide of Copper: its colour is a deep red, sometimes very lively, especially when bruised. It is friable, difficult of fusion at the blowpipe, reducible on burning charcoal, soluble with effervescence in nitric acid, forming a green liquid. Its constitution when pure, is 88·9 copper + 11·1 oxygen = 100.6.Black oxide of Copper, is of a velvet black, inclining sometimes to brown or blue; and it acquires the metallic lustre on being rubbed. It is infusible at the blowpipe. Its composition is, copper 80 + oxygen 20; being a true peroxide.7.Hydrosilicate of Copper, consists essentially of oxide of copper, silica, and water. Its colour is green; and its fracture is conchoidal with a resinous lustre, like most minerals which contain water. Its specific gravity is 2·73. It is infusible at the blowpipe alone, but it melts easily with borax.8.Dioptase Copper, orEmerald Malachite; a beautiful but rare cupreous mineral, consisting of oxide of copper, carbonate of lime, silica, and water in varying proportions.9.Carbonate of Copper,Malachite; is of a blue or green colour. It occurs often in beautiful crystals.10.Sulphate of Copper,Blue Vitriol, similar to the artificial salt of the laboratory. The blue water which flows from certain copper mines, is a solution of this salt. The copper is easily procured in the metallic state by plunging pieces of iron into it.11.Phosphate of Copper, is of an emerald green, or verdigris colour with some spots of black. It presents fibrous or tuberculous masses with a silky lustre in the fracture. It dissolves in nitric acid without effervescence, forming a blue liquid; melts at the blowpipe, and is reducible upon charcoal, with the aid of a little grease, into a metallic globule. Its powder does not colour flame green, like the powder of muriate of copper.12.Muriate of Copper, is green of various shades; its powder imparts to flame a remarkable blue and green colour. It dissolves in nitric acid without effervescence; and is easily reduced before the blowpipe. Its density is 3·5. By Klaproth’s analysis it consists of oxide of copper 73, muriatic acid 10, water 17.13.Arseniate of Copper.It occurs in beautiful blue crystals. Before the blowpipe it melts exhaling fumes of a garlic odour, and it affords metallic globules when in contact with charcoal. See more upon theoresat the end of this article.In the articleMetallurgy, I have described the mode of working certain copper mines; and shall content myself here with giving a brief account of two cupreous formations, interesting in a geological point of view; that of the copper slate of Mansfeldt, and of the copper veins of Cornwall.The curious strata of bituminous schist in the first of these localities, are among themost ancient of any which contain the exuviæ of organised bodies not testaceous. From among their tabular slabs the vast multitudes of fossil fish were extracted, which have rendered the cantons of Mansfeldt, Eisleben, Ilmenau, and other places in Thuringia and Voigtland so celebrated. Many of the fish are transformed into copper pyrites. Here, also, have been found the fossil remains of the lizard family, calledMonitors.Such is the influence of a wise administration upon the prosperity of mines, that the thin layer of slate in this formation, of which 100 pounds commonly contain but one pound and a half of copper, occasionally argentiferous, has been for several centuries the object of smelting works of the greatest importance to the territory of Mansfeldt and the adjoining country.The frequent derangements which this metallic deposit experiences, led skilful directors of the under-ground operations at an early period to study the order of superposition of the accompanying rocks. From their observations, there resulted a system of facts which have served to guide miners, not only in the country of Mansfeldt, but over a great portion of Germany, and in several other countries where the same series of rocks, forming the immediate envelope of the cupreous schists, were found to occur in the same order of superposition.Of the English copper works.—The deposits of copper in Cornwall occur always as veins in granite, or in the schistose rocks which surround and cover it; and hence, the Cornish miners work mostly in the granite or greenish clay slate; the former of which they callgrowan, the latterkillas. But tin is sometimes disseminated in small veins in porphyry orelvan, which itself forms great veins in the above rocks. No stratification has been observed in Cornwall.The copper veins are abundant in the killas and rare in the granite; but most numerous near the line of junction of the two rocks. The different kinds of mineral veins in Cornwall may be classed as follows:—1. Veins of elvan; elvan courses, or elvan channels.2. Tin veins, or tinlodes; the latter word being used by the Cornish miners to signify a vein rich in ore, and the wordcourse, to signify a barren vein.3. Copper veins running east and west; east and west copper lodes.4. Second system of copper veins, orcontracopper lodes.5. Crossing veins; cross courses.6. Modern copper veins; more recent copper lodes.7. Clay veins; of which there are two sets, the more ancient, calledCross-Fluckans; and the more modern, calledSlides.There are therefore three systems of copper veins in Cornwall; of which the first is considered to be the most ancient, because it is always traversed by the two others, and because, on the contrary, it never cuts them off. The width of these veins does not exceed 6 feet, though occasional enlargements to the extent of 12 feet sometimes take place. Their length is unknown, but the one explored in theUnited Mineshas been traced over an extent of seven miles. The gangue of these veins is generally quartz, either pure, or mixed with green particles analogous to chlorite. They contain iron pyrites, blende, sulphuret, and several other compounds of copper, such as the carbonate, phosphate, arseniate, muriate, &c. The most part of the copper veins are accompanied with small argillaceous veins, called by the minersfluckan of the lode. These are often found upon both sides of the vein, so as to form cheeks orsalebandes.When two veins intersect each other, the direction of the one thrown out becomes an object of interest to the miner and geologist. In Saxony it is regarded as a general fact that the rejected portion is always to the side of theobtuse angle; this also holds generally in Cornwall, and the more obtuse the angle of incidence, the more considerable the out-throw.The great copper vein ofCarharack, in the parish of Gwenap, is a most instructive example of intersection. The power of this vein is 8 feet; it runs nearly from east to west, and dips towards the north at an inclination of 2 feet in a fathom. Its upper part is in the killas, its lower part in the granite. The vein has suffered two intersections; the first results from encountering the vein calledSteven’s fluckan, which runs from north-east to south-west, throwing it out several fathoms. The second has been caused by another vein, almost at right angles to the first, and which has driven it 20 fathoms out to the right side. The fall of the vein occurs, therefore, in one case to the right, and in the other to the left; but in both instances, it is to the side of the obtuse angle. This disposition is very singular; for one portion of the vein appears to have ascended, while another has sunk.The mining works in the copper veins are carried on by reverse steps; seeMines. The grand shafts for drainage and extraction are vertical, and open upon the roof side of the vein, traversing it to a certain depth. These pits are sunk to the lowest point of the exploration; and, in proportion as the workings descend, by means of excavations in the vein, the pits are deepened and put into communication towards their bottom witheach new gallery of elongation, by means of transverse galleries. At present, the main shafts are fully 160 fathoms deep. Their horizontal section is oblong, and is divided into two compartments; the one destined for extraction, the other for the pumps. Their timbering has nothing remarkable, but is executed with every attention to economy, the whole wood employed in these mines being brought from Norway.The descent of the workmen is effected by inclined shafts scooped out of the vein; the ladders are slightly inclined; they are interrupted every 10 fathoms by floors; the steps are made of iron, and, to prevent them from turning under the foot, the form of a miner’s punch or jumper has been given them, the one end being round, and the other being wedge-shaped.The ore is raised either by means of horse-gins, or by steam-engine power most frequently of high pressure. I shall take theConsolidated Minesas an example.The draining, which is one of the most considerable sources of expense, both from the quantity of water, and from the depth of the mine, is executed by means of sucking and forcing pumps, the whole piston-rods of which, 120 feet long, are attached to a main-rod suspended at the extremity of the working beam of a steam-engine.On this mine three steam-engines are erected of very great power, for the purpose of drainage; the one called theMariaengine is of the first-rate force, and most improved construction. The cylinder is 90 inches in internal diameter, and the length of the stroke is 9 feet 11 inches. It works single stroke, and is encased in a coating of bricks to prevent dissipation of the heat. The vapour is admitted at the upper end of the cylinder during the commencement of the fall of the piston, at a pressure capable of forming an equilibrium with a column of 60 inches of mercury. The introduction of the steam ceases whenever the piston has descended through a certain space, which may be increased or diminished at pleasure. During the remainder of the descent the piston is pressed merely by this vapour in its progressive expansion, while the under side of the piston communicates with the condenser. It ascends by the counterweight at the pump end of the working beam. Hence, it is only during the descent of the piston, that the effective stroke is exerted. Frequently the steam is admitted only during the sixth part of the course of the piston, or 18 inches. In this way the power of the engine is proportioned to the work to be done; that is, to the body of water to be raised. Themaximumforce of the above engine is about 310 horses; though it is often made to act with only one third of this power.The copper mines of the isle of Anglesey, those of North Wales, of Westmoreland, the adjacent parts of Lancashire and Cumberland, of the south west of Scotland, of the Isle of Man, and of the south east of Ireland, occur also in primitive or transition rocks. The ores lie sometimes in masses, but more frequently in veins. The mine of Ecton in Staffordshire, and that of Cross-gill-burn, near Alston-moor in Cumberland, occur in transition or metalliferous limestone.The copper ores extracted both from the granitic and schistose localities, as well as from the calcareous, are uniformly copper pyrites more or less mixed with iron pyrites; the red oxide, carbonate, arseniate, phosphate, and muriate of copper, are very rare in these districts.The working of copper in the isle of Anglesey may be traced to a very remote era. It appears that the Romans were acquainted with the Hamlet mine near Holyhead; but it was worked with little activity till about 70 years ago. This metalliferous deposit lies in a greenish clay slate, passing into talc slate; a rock associated with serpentine and euphotide (gabbroof Von Buch). The veins of copper are from one to two yards thick; and they converge towards a point where their union forms a considerable mass of ore. On this mass the mine was first pierced by an open excavation, which is now upwards of 300 feet deep, and appears from above like a vast funnel. Galleries are formed at different levels upon the flank of the excavation to follow the several small veins, which run in all directions, and diverge from a common centre like so many radii. The ore receives in these galleries a kind of sorting, and is raised by means of hand windlasses, to the summit of a hill, where it is cleaned by breaking and riddling.The water is so scanty in this mine that it is pumped up by a six-horse steam-engine. A great proportion of it is charged with sulphate of copper. It is conveyed into reservoirs containing pieces of old iron; the sulphate is thus decomposed into copper of cementation. The Anglesea ore is poor, yielding only from 2 to 3per cent.of copper: a portion of its sulphur is collected in roasting the ore.Mechanical preparation of the copper ores in Cornwall.—The ore receives a first sorting, either within the mine itself, or at its mouth, the object of which is to separate all the pieces larger than a walnut. These are then reduced by the hammer to a smaller size; after which the whole are sorted into four lots, according to their relative richness. The fragments of poor ore are pounded in the stamps so that the metallic portion may be separated by washing.The rich ore is broken into small bits, of the size of a nut, with a flat beater, formedof a piece of iron 6 inches square and 1 inch thick, adapted to a wooden handle. The ore to be broken is placed upon plates of cast-iron; each about 16 inches square and 11⁄2inch thick. These iron plates are set towards the edge of a small mound about a yard high, constructed with dry stones rammed with earth. The upper surface of this mound is a little inclined from behind forwards. The work is performed by women, each furnished with a beater; the ore is placed in front of them beyond the plates; they break it, and strew it at their feet, whence it is lifted and disposed of to the smelting-houses.Inferior ores, containing a notable proportion of stony matters, are also broken with the beater, and the rich parts are separated by riddling and washing from the useless matters.The smaller ore is washed on a sieve by shaking it in a stream of water, which carries away the lighter stony pieces, and leaves the denser metalliferous. They are then sorted by hand. Thus by beating, stamping, and riddling in water, the stony substances are in a great measure separated. The finer ground matter is washed on a plane table, over which a current of water is made to flow. Finally, the ore nearly fine is put into a large tub with water, and briskly stirred about with a shovel, after which it settles in the order of richness, the pure metallic ore being nearest the bottom. The stamps used for copper ore in Cornwall are the same as those used for tin ores, of which we shall speak in treating of the latter metal, as well as of the boxes for washing the fine powder orslime. These in fact do not differ essentially from the stamping mills and washing apparatus described in the articleMetallurgy. Crushing rolls are of late years much employed. SeeLeadandTin.Cornwall being destitute of coal, the whole copper ore which this county produces is sent for smelting to South Wales. Here are 15 copper works upon the Swansea and Neath, which pursue a nearly uniform and much improved process, consisting in a series of calcinations, fusions, and roastings, executed upon the ores and the matters resulting from them.The furnaces are of the reverberatory construction; they vary in their dimensions and in the number of their openings, according to the operations for which they were intended. There are 5 of them:—1. The calcining furnace or calciner; 2. The melting furnace; 3. The roasting furnace or roaster; 4. The refining furnace; 5. The heating or igniting furnace.Calcining furnace1. The calcining furnace rests upon a vault,C, into which the ore is raked down after being calcined; it is built of bricks, and bound with iron bars, as shown in the elevation,fig.296.The hearth,B B,figs.296.and298.is placed upon a level with the lower horizontal binding bar, and has nearly the form of an ellipse, truncated at the two extremities of its great axis. It is horizontal, bedded with fire-bricks set on edge, so that it may be removed and repaired without disturbing the arch upon which it reposes. Holes, not visible in the figure, are left in the shelves before each door,c c, through which the roasted ore is let fall into the subjacent vault. The dimensions of the hearthB Bare immense, being from 17 to 19 feet in length, and from 14 to 16 in breadth. The fire-place,A,fig.298., is from 41⁄2to 5 feet long, and 3 feet wide. The bridge or low wall,b,fig.302., which separates the fire-place from the hearth, is 2 feet thick; and in Mr. Vivian’s smelting-works is hollow, as shown in the figure, and communicates at its two ends with the atmosphere, in order to conduct a supply of fresh air to the hearth of the furnace. This judicious contrivance will be described in explaining theroastingoperation. The arched roof of the furnace slopes down from the bridge to the beginning of the chimney,f,fig.296,298., its height above the hearth being at the first point about 26 inches, and from 8 to 12 at the second.Such great calcining furnaces have 4 or 5 doors,c c c c,fig.298., one for the fire-place, as shown at the right hand infig.297., and 3 or 4 others for working the ore upon thereverberatory hearth. If there be 3, 2 of them are placed between the vertical binding bars upon one side, and a third upon the opposite side of the furnace; if there be 4, 2 are placed upon each side, facing one another. These openings are 12 inches square, and are bound with iron frames. The chimney is about 22 feet high, and is placed at one angle of the hearth, as atf,fig.298., being joined by an inclined flue to the furnace.For charging it with ore there is usually placed above the upper part of the vault 2 hoppers,E E, in a line with the doors; they are formed of 4 plates of iron, supported in an iron frame. Beneath each of them there is an orifice for letting the ore down into the hearth.These furnaces serve for calcining the ore, and themattsorcrude coppers: for the latter purpose, indeed, furnaces of two stories are sometimes employed, as represented infig.301.The dimensions of each floor in this case are a little less than the preceding. Two doors,c c, correspond to each hearth, and the workmen, while employed at the upper story, stand upon a raised movable platform.Melting furnace2.Melting furnace,figs.299and300.—The form of the hearth is also elliptical, but the dimensions are smaller than in the calcining furnace. The length does not exceed 11 or 111⁄2feet, and the breadth varies from 7 to 8. The fire-place is however larger in proportion, its length being from 31⁄2feet to 4, and its breadth from 3 to 31⁄2; this size being requisite to produce the higher temperature of this furnace. It has fewer openings, there being commonly three; one to the fire-place atD, a second one,O, in the side, kept generally shut, and used only when incrustations need to be scraped off the hearth, or when the furnace is to be entered for repairs; and the third or working-door,G, placed on the front of the furnace beneath the chimney. Through it the scoriæ are raked out, and the melted matters are stirred and puddled, &c.The hearth is bedded with infusible sand, and slopes slightly towards the side door, to facilitate the discharge of the metal. Above this door there is a hole in the wall of the chimney (fig.300.) for letting the metal escape. An iron gutter,O, leads it into a pit,K, bottomed with an iron receiving-pot, which may be lifted out by a crane. The pitMis filled with water, and the metal becomes granulated as it falls into the receiver. The melting furnaces are surmounted by a hopper,L, as shown infig.299.Melting cum calcination furnaceMelting furnaces are sometimes used also for calcination. There are some such near Swansea, which serve this double purpose; they are composed of 3 floors (fig.301.) The floorAis destined for melting the calcined ore; the other two,B C, serve for calcination. The heat being less powerful, upon the upper soleC, the ore gets dried upon it, and begins to be calcined—a process completed on the next floor. Square holes,d, left in the hearthsBandC, put them in communication with each other, and with the lower oneA; these perforations are shut during the operation by a sheet of iron, removable at pleasure.The hearthsbandcare made of bricks; they are horizontal at top and slightly vaulted beneath; they are 2 bricks thick, and their dimensions are larger than those of the inferior hearths, as they extend above the fire-place. On the floors destined for calcination the furnace has two doors on one of its sides: on the lower story there are also two; but they are differently collocated. The first, being in the front of the furnace, serves for drawing off the scoriæ, for working the metal, &c.; and the second, upon the side, admits workmen to make necessary repairs. Below this door the discharge or tap-holeAis placed, which communicates by a cast-iron gutter with a pit filled with water. The dimensions of this furnace in length and breadth are nearly the same as those of the melting furnace above described; the total height is nearly 12 feet. It is charged by means of one or two hoppers.3.Roasting furnace.—The furnaces employed for this purpose are in general analogous to the calcining ones; but in the smelting works of Hafod, the property of Messrs. Vivian, these furnaces, alluded to above, present a peculiar construction, for the purpose of introducing a continuous current of air upon the metal, in order to facilitate its oxidizement. This process was originally invented by Mr. Sheffield, who disposed of his patent right to Messrs. Vivian.Bridge between hearth and fire-placeThe air is admitted by a channel,c c, through the middle of the fire-bridge,fig.302, and extending all its length; it communicates with the atmosphere at its two endsc c; square holes,b b, left at right angles to this channel, conduct the air into the furnace.This very simple construction produces a powerful effect in the roasting operation. It not only promotes the oxidizement of the metals, but burns the smoke, and assists in the vaporisation of the sulphur; while by keeping the bridge cool it preserves it from wasting, and secures uniformity of temperature to the hearth.4.Refining furnace.—In this, as in the melting furnace, the sole slopes towards the door in front, instead of towards the side doors, because in the refining furnace the copper collects into a cavity formed in the hearth towards the front door, from which it is lifted out by ladles; whereas, in the melting furnaces, the metal is run out by a tap-hole in the side. The hearth sole is laid with sand; but the roof is higher than in the melting furnace, being from 32 to 36 inches. If the top arch were too much depressed, there might be produced upon the surface of the metal a layer of oxide very prejudicial to the quality of the copper. When the metal in that case is run out, its surface solidifies and cracks, while the melted copper beneath breaks through and spreads irregularly over the cake. This accident, called therising of the copper, hinders it from being laminated, and requires it to be exposed to a fresh refining process, when lead must be added to dissolve the oxide of copper. This is the only occasion upon which the addition of lead is proper in refining copper. When the metal to be refined is mixed with others, particularly with tin, as in extracting copper from old bells, then very wide furnaces must be employed, to expose the metallic bath upon a great surface, and in a thin stratum, to the oxidizing action of the air.The doorG,fig.300., upon the side of the refining furnace, is very large, and is shut with a framed brick door, balanced by a counter-weight. This door being open during the refining process, the heat is stronger atBthan atA(figs.299,300.)5.Heating furnaces, being destined to heat the pigs or bars of copper to be laminated, as well as the copper sheets themselves, are made much longer in proportion to their breadth. Their hearth is horizontal, the vault not much depressed; they have only one door, placed upon the side, but which extends nearly the whole length of the furnace: this door may be raised by means of a counter-weight, in the same way as in the furnaces for the fabrication of sheet-iron and brass.Series of operations to which the ore is subjected.—The ores which are smelted in the Swansea works are cupreous pyrites, more or less mingled withgangue(vein-stone). The pyrites is composed of nearly equal proportions of sulphuret of copper and sulphuret of iron.The earthy matters which accompany the pyrites are usually siliceous, though in some mines the metalliferous deposit is mixed with clay or fluate of lime. Along with these substances, pretty uniformly distributed, tin and arsenical pyrites occur occasionally with the copper; and though these two metals are not chemically combined, yet they cannot be separated entirely in the mechanical preparations. The constituent parts of the ore prepared for smelting are, therefore, copper, iron, sulphur, with tin, arsenic, and earthy matters in some cases. The different ores are mixed in such proportions that the average metallic contents may amount to 81⁄2per cent. The smelting process consists in alternate roastings and fusions. The following description of it is chiefly taken from an excellent paper, published by John Vivian, esq., in the Annals of Philosophy for 1823.In the roasting operation the volatile substances are disengaged mostly in the gaseous state, while the metals that possess a strong affinity for oxygen become oxidized. In the fusion the earthy substances combine with these oxides, and form glassy scoriæ or slags, which float upon the surface of the melted metal.These calcinations and fusions take place in the following order:—1. Calcination of the ore. 2. Melting of the calcined ore. 3. Calcination of the coarse metal. 4. Melting of the calcined coarse metal. 5. Calcination of the fine metal (second matt). 6. Melting of the calcined fine metal. 7. Roasting of the coarse copper. In some smelting works, this roasting is repeated four times; in which case a calcination and a melting are omitted. In the Havod works, however, the same saving is made without increasing the number of roastings. 8. Refining or toughening the copper.Besides these operations, which constitute the treatment of copper properly speaking, two others are sometimes performed, in which only the scoriæ are melted. These may be designated by the lettersaandb.ais the re-melting of the portion of the scoriæ of the second process, which contain some metallic granulations.bis a particular melting of the scoriæ of the fourth operation. This fusion is intended to concentrate the particles of copper in the scoriæ, and is not practised in all smelting works.First operation. Calcination of the ore.—The different ores, on arriving from Cornwall and other districts where they are mined, are discharged in continuous cargoes at the smelting works, in such a way, that by taking out a portion from several heaps at a time, a tolerably uniform mixture of ores is obtained; which is very essential in a foundry, because, the ores being different in qualities and contents, they act asfluxes upon each other. The ore thus mixed is transported to the works in wooden measures that hold a hundred-weight. The workmen entrusted with the calcination convey the ore into the hoppers of the calcining furnace, whence it falls into the hearth; other workmen spread it uniformly on the surface by iron rakes. The charge of a furnace is from three tons to three tons and a half. Fire is applied and gradually increased, till, towards the end of the operation, the temperature be as high as the ore can support without melting or agglutinating. To prevent this running together, and to aid the extrication of the sulphur, the surfaces are renewed, by stirring up the ore at the end of every hour. The calcination is usually completed at the end of 12 hours, when the ore is tumbled into the arch under the sole of the furnace. Whenever the ore is cold enough to be moved, it is taken out of the arch, and conveyed to the calcined heap.The ore in this process hardly changes weight, having gained in oxidizement nearly as much as it has lost in sulphur and arsenic; and if the roasting has been rightly managed, the ore is in a black powder, owing to the oxide of iron present.Second operation. Fusion of the calcined ore.—The calcined ore is likewise given to the melters in measures containing a hundred-weight. They toss it into hoppers, and after it has fallen on the hearth, they spread it uniformly. They then let down the door, and lute it tightly. In this fusion there are added about 2 cwt. of scoriæ proceeding from the melting of the calcined matt, to be afterwards described. The object of this addition is not only to extract the copper that these scoriæ may contain, but especially to increase the fusibility of the mixture. Sometimes also, when the composition of the ore requires it, lime, sand, or fluor spar is added; and particularly the last fluxing article.The furnace being charged, fire is applied, and the sole care of the founder is to keep up the heat so as to have a perfect fusion; the workman then opens the door, and stirs about the liquid mass to complete the separation of the metal (or rather of the matt) from the scoriæ, as well as to hinder the melted matter from sticking to the sole. The furnace being ready, that is, the fusion being perfect, the founder takes out the scoriæ by the front door, by means of a rake. When the matt is thus freed from the scoriæ, a second charge of calcined ore is then introduced to increase the metallic bath; which second fusion is executed like the first. In this way, new charges of roasted ore are put in till the matt collected on the hearth rises to a level with the door-way, which happens commonly after the third charge. The tap hole is now opened; the matt flows out into the pit filled with water, where it is granulated during its immersion; and it collects in the pan placed at the bottom. The granulated matt is next conveyed into the matt warehouse. The oxidation with which the grains get covered by the action of the water, does not allow the proper colour of the matt or coarse metal to be distinguished; but in the bits which stick in the gutter, it is seen to be of a steel gray. Its fracture is compact, and its lustre metallic. The scoriæ often contain metallic grains; they are broken and picked with care. All the portions which include some metallic particles are re-melted in an accessory process. The rejected scoriæ have been found to be composed of siliceous matter 59, oxide of copper 1, oxide of tin 0·7.In this operation, the copper is concentrated by the separation of a great part of the matters with which it was mixed or combined. The granulated matt produced, contains in general 33 per cent. of copper; it is therefore four times richer than the ore; and its mass is consequently diminished in that proportion. The constituent parts are principally copper, iron, and sulphur.The most important point to hit in the fusion just described, is to make a fusible mixture of the earths and the oxides, so that the matt of copper may, in virtue of its greater specific gravity, fall to the under-part, and separate exactly from the slag. This point is attained by means of the metallic oxides contained in the scoriæ of the fourth operation, of which 2 cwt. were added to the charge. These consist almost entirely of black oxide of iron. When the ores are very difficult to melt, a measure of about half a hundred-weight of fluor spar is added; but this must be done with precaution, for fear of increasing the scoriæ too much.The business goes on day and night. Five charges are commonly put through hands in the course of 24 hours; but when all circumstances are favourable, that is to say, when the ore is fusible, when the fuel is of the first quality, and when the furnace is in good condition, even six charges a day have been despatched.The charge is a ton and a half of calcined ore, so that a melting furnace corresponds nearly to a calcining furnace; the latter turning out nearly 7 tons of calcined ore in 24 hours.The workmen are paid by the ton.Third operation. Calcination of the coarse metal, or the matt.—The object of this operation is principally to oxidize the iron, an oxidation easier to execute, than in the firstcalcining, because the metal is now disengaged from the earthy substances, which screened it from the action of the air.This calcination is executed in the furnace already represented,fig.296,297,298.page 318.exactly in the same way as the ore was calcined. The metal must be perpetually stirred about, to expose all its surfaces to the action of the hot air, and to hinder the clotting together. The operation lasts 24 hours; during the first six, the fire should be very moderate, and thereafter gradually increased to the end of the calcination. The charge is, like that of the first, 3 tons and a half.Fourth operation. Melting of the calcined coarse metal, or calcined matt.—In the fusion of this first calcined matt, some scoriæ of the latter operations must be added, which are very rich in oxide of copper, and some crusts from the hearth, which are likewise impregnated with it. The proportion of these substances varies according to the quality of the calcined matt.In this second fusion, the oxide of copper contained in the scoriæ, is reduced by the affinity of the sulphur, one portion of which passes to the state of acid, while the other forms a subsulphuret with the copper become free. The matt commonly contains a sufficient quantity of sulphur to reduce the oxide of copper completely; but if not, which may happen if the calcination of the matt has been pushed too far, a small quantity of uncalcined matt must be introduced, which, by furnishing sulphur, diminishes the richness of the scoriæ, and facilitates the fusion.The scoriæ are taken out by the front door, by drawing them forward with a rake. They have a great specific gravity; are brilliant with metallic lustre, very crystalline, and present, in the cavities, crystals like those of pyroxene; they break easily into very sharp-edged fragments. They contain no granulated metal in the interior; but it sometimes occurs, on account of the small thicknesses of the stratum of scoriæ, that these carry off with them, when they are withdrawn, some metallic particles.These scoriæ, as we have already stated, under the fusion of the roasted ore, are in general melted with it. In some cases, however, a special melting is assigned to them.The matt obtained in this second fusion is either run out into water like the first, or moulded into pigs (ingots), according to the mode of treatment which it is to undergo. This matt, called by the smeltersfine metalwhen it is granulated, andblue metalwhen it is in pigs, is of a light grey colour, compact, and bluish at the surface. It is collected in the first form when it is to be calcined anew; and in the second, when it must immediately undergo the operation ofroasting. Its contents in copper are 60per cent.This operation, which is but sometimes had recourse to, lasts 5 or 6 hours. The charge is 1 ton.(b)Particular fusion of the scoriæ of the fourth operation.—In re-melting these scoriæ, the object is to procure the copper which they contain. To effect this fusion, the scoriæ are mixed with pulverized coal, or other carbonaceous matters. The copper and several other metals are deoxidized, and furnish a white and brittle alloy. The scoriæ resulting from this melting are in part employed in the first melting, and in part thrown away. They are crystalline, and present crystals often in the cavities, which appear to belong to bisilicate of iron. They have a metallic lustre, and break into very sharp-edged fragments. The white metal is melted again, and then united to the product of the second fusion.Fifth operation. Calcination of the second matt, or fine metal of the smelter.—This is executed in precisely the same way as that of the first matt. It lasts 24 hours; and the charge is usually 3 tons.Sixth operation. Melting of the calcined fine metal.—This fusion is conducted like that of the first matt. The black copper, or coarse copper, which it produces, contains from 70 to 80 per cent. of pure metal; it is run into ingots, in order to undergo the operation of roasting.The scoriæ are rich in copper; they are added to the fusion of the calcined coarse metal of the fourth operation.In the smelting houses of Messrs. Vivian, at Hafod, near Swansea, the fifth and sixth operations have been omitted of late years. The second matt is run into pigs, under the name ofblue metal, to be immediately exposed to the roasting.The disposition of the canalaa′,fig.302., which introduces a continuous current of air to the hearth of the furnace, accelerates and facilitates the calcination of the matt; an advantage which has simplified the treatment, by diminishing the number of calculations.Seventh operation. Roasting of the coarse copper, the product of the sixth operation.The chief object of this operation is oxidizement; it is performed either in an ordinary roasting furnace, or in the one belonging tofig.302., which admits a constant current of air. The pigs of metal derived from the preceding melting are exposed, on the hearth of the furnace, to the action of the air, which oxidizes the iron and other foreign metals with which the copper is still contaminated. The duration of the roasting varies from12 to 24 hours, according to the degree of purity of the crude copper. The temperature should be graduated, in order that the oxidizement may have time to complete, and that the volatile substances which the copper still retains may escape in the gaseous form. The fusion must take place only towards the end of the operation.The charge varies from a ton and a quarter to a ton and a half. The metal obtained is run out into moulds of sand. It is covered with black blisters, like steel of cementation; whence it has got the name of blistered copper. In the interior of these pigs, the copper presents a porous texture, occasioned by the ebullition produced by the escape of the gases during the moulding. The copper being now almost entirely purged from the sulphur, iron, and the other substances with which it was combined, is in a fit state to be refined. This operation affords some scoriæ; they are very heavy, and contain a great deal of oxide of copper, sometimes even metallic copper.These scoriæ, as well as those of the third melting and of the refining, are added to the second fusion, as we have already stated, in describing the fourth operation.In some works, the roasting is repeated several times upon theblue metal, in order to bring it to a state fit for refining. We shall afterwards notice this modification of the treatment.Eighth operation. Refining or toughening.—The pigs of copper intended for refining are put upon the sole of the refining furnace through the door in the side. A slight heat is first given, to finish the roasting or oxidation, in case this operation has not already been pushed far enough. The fire is to be increased by slow degrees, so that, by the end of 6 hours, the copper may begin to flow. When all the metal is melted, and when the heat is considerable, the workman lifts up the door in the front, and withdraws with a rake the few scoriæ which may cover the copper bath. They are red, lamellated, very heavy, and closely resemble protoxide of copper.The refiner takes then an assay with a small ladle, and when it cools, breaks it in a vice, to see the state of the copper. From the appearance of the assay, the aspect of the bath, the state of the fire, &c., he judges if he may proceed to the toughening, and what quantity of wooden spars and wood charcoal he must add to render the metal malleable, or, in the language of the smelters, bring it to the proper pitch. When the operation of refining begins, the copper is brittle or dry, and of a deep red colour approaching to purple. Its grain is coarse, open, and somewhat crystalline.To execute the refining, the surface of the metal is covered over with wood charcoal, and stirred about with a spar or rod of birch wood. The gases which escape from the wood, occasion a brisk effervescence. More wood charcoal is added from time to time, so that the surface of the metal may be always covered with it, and the stirring is continued with the rods, till the operation of refining be finished; a circumstance indicated by the assays taken in succession. The grain of the copper becomes finer and finer, and its colour gradually brightens. When the grain is extremely fine, orclosed, when the trial pieces half cut through and then broken, present a silky fracture, and when the copper is of a fine light red, the refiner considers the operation to be completed; but he verifies still further the purity of the copper, by trying its malleability. For this purpose, he takes out a sample in his small ladle, and pours it into a mould. When the copper is solidified, but still red-hot, he forges it. If it is soft under the hammer, if it does not crack on the edges, the refiner is satisfied with its ductility, and he pronounces it to be in itsproper state. He orders the workmen to mould it; who then lift the copper out of the furnace in large iron ladles lined with clay, and pour it into moulds of the size suitable to the demands of commerce. The ordinary dimensions of the ingots or pigs are 12 inches broad, 18 long, and from 2 to 21⁄2thick.The period of the refining process is 20 hours. In the first six, the metal heats, and suffers a kind of roasting; at the end of this time it melts. It takes four hours to reach the point at which the refining, properly speaking, begins; and this last part of the process lasts about 4 hours. Finally, 6 hours are required to arrange the moulds, cast the ingots, and let the furnace cool.The charge of copper in the refining process depends upon the dimensions of the furnace. In the Hafod works, one of the most important in England, the charge varies from 3 to 5 tons; and the quantity of pure copper manufactured in a week is from 40 to 50 tons.The consumption of fuel is from 15 to 18 parts of coal, for one part of refined copper in pigs.When the copper offers difficulties in the refining, a few pounds of lead are added to it. This metal, by the facility with which it scorifies, acts as a purifier, aiding the oxidation of the iron and other metals that may be present in the copper. The lead ought to be added immediately after removing the door to skim the surface. The copper should be constantly stirred up, to expose the greatest possible surface to the action of the air, and to produce the complete oxidation of the lead; for the smallest quantity of this metal alloyed in copper, is difficult to clear up in the lamination; that is to say, the scale of oxide does not come cleanly from the surface of the sheets.The operation of refining copper is delicate, and requires, upon the part of the workmen, great skill and attention to give the metal its due ductility. Its surface ought to be entirely covered with wood charcoal; without this precaution, the refining of the metal wouldgo back, as the workmen say, during the long interval which elapses in the moulding; whenever this accident happens, the metal must be stirred up anew with the wooden pole.Too long employment of the wooden rod gives birth to another remarkable accident, for the copper becomes more brittle than it was prior to the commencement of the refining; that is, when it wasdry. Its colour is now of a very brilliant yellowish red, and its fracture is fibrous. When this circumstance occurs, when the refining, as the workmen say, hasgone too far, the refiner removes the charcoal from the top of the melted metal; he opens the side door, to expose the copper to the action of the air, and it then resumes its malleable condition.Mr. Vivian, to whom we owe the above very graphic account of the processes, has explained, in a very happy manner, the theory of refining. He conceives, we may conclude, that the copper in thedry state, before the refining, is combined with a small portion of oxygen, or, in other words, that a small portion of oxide of copper is diffused through the mass, or combined with it; and that this proportion of oxygen is expelled by the deoxidizing action of the wood and charcoal, whereby the metal becomes malleable. 2. That when the refining process is carried too far, the copper gets combined with a little charcoal. Thus copper, like iron, is brittle when combined with oxygen and charcoal; and becomes malleable only when freed entirely from these two substances.It is remarkable, that copper, in thedry state, has a very strong action upon iron; and that the tools employed in stirring the liquid metal become very glistening, like those used in a farrier’s forge. The iron of the tools consumes more rapidly at that time, than when the copper has acquired its malleable state. The metal requires, also, whendry, more time to become solid, or to cool, than when it is refined; a circumstance depending, probably, upon the difference in fusibility of the copper in the two states, and which seems to indicate, as in the case of iron, the presence of oxygen.When the proper refining point has been passed, another very remarkable circumstance has been observed; namely, that the surface of the copper oxidizes more difficultly, and that it is uncommonly brilliant; reflecting clearly the bricks of the furnace vault. This fact is favourable to the idea suggested above, that the metal is in that case combined with a small quantity of carbon; which absorbs the oxygen of the air, and thus protects the metal from its action.Copper is brought into the market in different forms, according to the purposes which it is to serve. What is to be employed in the manufacture of brass is granulated. In this condition it presents more surface to the action of zinc or calamine, and combines with it more readily. To produce this granulation, the metal is poured into a large ladle, pierced with holes, and placed above a cistern filled with water, which must be hot or cold, according to the form wished in the grains. When it is hot, round grains are obtained analogous to lead shot; and the copper in this state is calledbean shot. When the melted copper falls into cold water perpetually renewed, the granulations are irregular, thin, and ramified; constitutingfeathered shot. Thebean shotis the form employed in brass making.Copper is also made into small ingots, about 6 ounces in weight. These are intended for exportation to the East Indies, and are known in commerce by the name of Japan copper. Whenever these little pieces are solidified, they are thrown, while hot, into cold water. This immersion slightly oxidizes the surface of the copper, and gives it a fine red colour.Lastly, the copper is often reduced into sheets, for the sheathing of ships, and many other purposes. The Hafod works possess a powerful rolling mill, composed of four pairs of cylinders. It is moved by a steam engine, whose cylinder has 40 inches diameter. See the representation of therolling millof the Royal Mint, underGold.The cylinders for rolling copper into sheets are usually 3 feet long, and 15 inches in diameter. They are uniform. The upper roller may be approached to the under one, by a screw, so that the cylinders are brought closer, as the sheet is to be made thinner.The ingots of copper are laid upon the sole of a reverberatory furnace to be heated; they are placed alongside each other, and they are formed into piles in a cross-like arrangement, so that the hot air may pass freely round them all. The door of the furnace is shut, and the workman looks in through a peep-hole from time to time, to see if they have taken the requisite temperature; namely, a dull red. The copper is now passed between the cylinders; but although this metal be very malleable, the ingots cannot be reduced to sheets without being several times heated; because the copper cools, and acquires, by compression, a texture which stops the progress of the lamination.These successive heatings are given in the furnace indicated above; though, when thesheets are to have a very great size, furnaces somewhat different are had recourse to. They are from 12 to 15 feet long, and 5 wide. SeeBrass.The copper, by successive heating and lamination, gets covered with a coat of oxide, which is removed by steeping the sheets for a few days in a pit filled with urine; they are then put upon the sole of the heating furnace. Ammonia is formed, which acts on the copper oxide, and lays bare the metallic surface. The sheets are next rubbed with a piece of wood, then plunged, while still hot, into water, to make the oxide scale off; and lastly, they are passed cold through the rolling press to smooth them. They are now cut square, and packed up for home sale or exportation.The following estimate has been given by MM. Dufrénoy and Elie de Beaumont of the expense of manufacturing a ton of copper in South Wales.£s.d.121⁄2tons of ore, yielding 81⁄2per cent.of copper550020 tons of coals800Workmen’s wages, rent, repairs, &c.13007600The exhalations from the copper smelting works are very detrimental to both vegetable and animal life. They consist of sulphurous acid, sulphuric acid, arsenic and arsenious acids, various gases and fluoric vapours, with solid particles mechanically swept away into the air, besides the coal smoke. Mr. Vivian has invented a very ingenious method of passing the exhalations from the calcining ores andmattsalong horizontal flues or rather galleries of great dimensions, with many crossings and windings of the current, and exposure during the greater part of the circuit to copious showers of cold water. By this simple and powerful system of condensation, the arsenic is deposited in the bottoms of the flues, the sulphurous acid is in a great measure absorbed, and the nuisance is remarkably abated.The following figures represent certain modifications of the copper calcining and smelting copper furnaces of Swansea.
COPPER is one of the metals most anciently known. It was named from the island of Cyprus, where it was extensively mined and smelted by the Greeks. It has a reddish brown colour inclining to yellow; a faint but nauseous and rather disagreeable taste; and when rubbed between the fingers it imparts a smell somewhat analogous to its taste. Its specific gravity is from 8·8 to 8·9. It is much more malleable than it is ductile; so that far finer leaves may be obtained from it than wire. It melts at the 27th degree of Wedgewood’s pyrometer, and at a higher temperature it evaporates in fumes which tinge the fire of a bluish green. By exposure to heat with access of air, it is rapidly converted into black scales of peroxide. In tenacity it yields to iron; but surpasses gold, silver, and platinum, considerably in this respect.
In mineralogy, the genus copper includes about 13 different species, and each of these contains a great many varieties. These ores do not possess any one general exterior character by which they can be recognized; but they are readily distinguished by chemical re-agents. Water of ammonia digested upon any of the cupreous ores in a pulverized state, after they have been calcined either alone or with nitre, assumes an intense blue colour, indicative of copper. The richest of the ordinary ores appear under two aspects; the first class has a metallic lustre, a copper red, brass yellow, iron gray, or blackish gray colour, sometimes inclining to blue; the second is without metallic appearance, has a red colour, verging upon purple, blue, or green, the last tint being the most usual. Few copper ores are to be met with, indeed, which do not betray the presence of this metal by more or less of a greenish film.
1.Native copper, occurs in crystals, branches and filaments, its most common locality being in primitive rocks. It is found abundantly in Siberia, at the mines of Tourinski, in those of Hungary, of Fundo-Moldavi in Gallicia, of Fahlun in Sweden,of Cornwall, &c. The gangues of native copper are granite, gneiss, mica-slate, clay-slate, quartz, carbonate or fluate of lime, sulphate of barytes, &c. The most remarkable masses of native copper hitherto observed were; first, one in Brazil, 14 leagues from Basa, which weighed 2616 pounds; and secondly, another which Dr. Francis-le-Baron discovered in America to the south of Lake Superior. It was nearly 15 feet in circumference.
2.Sulphuret of Copper, the vitreous ore of Brochant.The texture of this ore is compact: its fracture, conchoidal, surface sometimes dull; colour, iron black or lead gray, often bluish, iridescent, or reddish from a mixture of protoxide. It is easily melted even by the heat of a candle; but more difficult of reduction than protoxide. This ore yields to the knife, assuming a metallic lustre when cut. Its density varies from 4·8 to 5·34. Its composition according to Klaproth is 78·5 copper, 18·5 sulphur, with a little iron and silica. Its equivalent constitution by theory is 80 copper + 20 sulphur = 100; whence 78·5 of metal should be associated with 19·6 of sulphur. This ore is therefore one of the richest ores, and forms very powerful veins, which likewise contain some orange protoxide. It is to be found in all considerable copper districts; in Siberia, Saxony, Sweden, and especially Cornwall, where the finest crystals occur.
3.Copper Pyrites, resembles in its metallic yellow hue, sulphuret of iron; but the latter is less pale, harder, and strikes fire more easily with steel. It presents the most lively rainbow colours. Its specific gravity is 4·3. It contains generally a good deal of iron; as the following analysis will show; copper 30, sulphur 37, iron 33, in 100 parts. According to Hisinger, the Swedish pyrites contains 63 of copper, 12 of iron, and 25 of sulphur. These ores occur in primitive and transition districts in vast masses and powerful veins; and are commonly accompanied with gray copper, sulphuret of iron, sparry iron, sulphurets of lead, and zinc.
4.Gray Copper, has a steel gray colour, more or less deep, either shining or dull; fracture uneven; a distinct metallic lustre; difficult of fusion at the blowpipe; it communicates to glass of borax a yellowish-red colour. Its density in crystals is 4·86. Its composition is very variable; consisting essentially of copper, iron, antimony, and sulphur. The exploration of this ore is profitable, in consequence of the silver which it frequently contains. It occurs in primitive mountains; and is often accompanied with red silver ore, copper pyrites, and crystallized quartz.
5.Protoxide of Copper, orred oxide of Copper: its colour is a deep red, sometimes very lively, especially when bruised. It is friable, difficult of fusion at the blowpipe, reducible on burning charcoal, soluble with effervescence in nitric acid, forming a green liquid. Its constitution when pure, is 88·9 copper + 11·1 oxygen = 100.
6.Black oxide of Copper, is of a velvet black, inclining sometimes to brown or blue; and it acquires the metallic lustre on being rubbed. It is infusible at the blowpipe. Its composition is, copper 80 + oxygen 20; being a true peroxide.
7.Hydrosilicate of Copper, consists essentially of oxide of copper, silica, and water. Its colour is green; and its fracture is conchoidal with a resinous lustre, like most minerals which contain water. Its specific gravity is 2·73. It is infusible at the blowpipe alone, but it melts easily with borax.
8.Dioptase Copper, orEmerald Malachite; a beautiful but rare cupreous mineral, consisting of oxide of copper, carbonate of lime, silica, and water in varying proportions.
9.Carbonate of Copper,Malachite; is of a blue or green colour. It occurs often in beautiful crystals.
10.Sulphate of Copper,Blue Vitriol, similar to the artificial salt of the laboratory. The blue water which flows from certain copper mines, is a solution of this salt. The copper is easily procured in the metallic state by plunging pieces of iron into it.
11.Phosphate of Copper, is of an emerald green, or verdigris colour with some spots of black. It presents fibrous or tuberculous masses with a silky lustre in the fracture. It dissolves in nitric acid without effervescence, forming a blue liquid; melts at the blowpipe, and is reducible upon charcoal, with the aid of a little grease, into a metallic globule. Its powder does not colour flame green, like the powder of muriate of copper.
12.Muriate of Copper, is green of various shades; its powder imparts to flame a remarkable blue and green colour. It dissolves in nitric acid without effervescence; and is easily reduced before the blowpipe. Its density is 3·5. By Klaproth’s analysis it consists of oxide of copper 73, muriatic acid 10, water 17.
13.Arseniate of Copper.It occurs in beautiful blue crystals. Before the blowpipe it melts exhaling fumes of a garlic odour, and it affords metallic globules when in contact with charcoal. See more upon theoresat the end of this article.
In the articleMetallurgy, I have described the mode of working certain copper mines; and shall content myself here with giving a brief account of two cupreous formations, interesting in a geological point of view; that of the copper slate of Mansfeldt, and of the copper veins of Cornwall.
The curious strata of bituminous schist in the first of these localities, are among themost ancient of any which contain the exuviæ of organised bodies not testaceous. From among their tabular slabs the vast multitudes of fossil fish were extracted, which have rendered the cantons of Mansfeldt, Eisleben, Ilmenau, and other places in Thuringia and Voigtland so celebrated. Many of the fish are transformed into copper pyrites. Here, also, have been found the fossil remains of the lizard family, calledMonitors.
Such is the influence of a wise administration upon the prosperity of mines, that the thin layer of slate in this formation, of which 100 pounds commonly contain but one pound and a half of copper, occasionally argentiferous, has been for several centuries the object of smelting works of the greatest importance to the territory of Mansfeldt and the adjoining country.
The frequent derangements which this metallic deposit experiences, led skilful directors of the under-ground operations at an early period to study the order of superposition of the accompanying rocks. From their observations, there resulted a system of facts which have served to guide miners, not only in the country of Mansfeldt, but over a great portion of Germany, and in several other countries where the same series of rocks, forming the immediate envelope of the cupreous schists, were found to occur in the same order of superposition.
Of the English copper works.—The deposits of copper in Cornwall occur always as veins in granite, or in the schistose rocks which surround and cover it; and hence, the Cornish miners work mostly in the granite or greenish clay slate; the former of which they callgrowan, the latterkillas. But tin is sometimes disseminated in small veins in porphyry orelvan, which itself forms great veins in the above rocks. No stratification has been observed in Cornwall.
The copper veins are abundant in the killas and rare in the granite; but most numerous near the line of junction of the two rocks. The different kinds of mineral veins in Cornwall may be classed as follows:—
1. Veins of elvan; elvan courses, or elvan channels.
2. Tin veins, or tinlodes; the latter word being used by the Cornish miners to signify a vein rich in ore, and the wordcourse, to signify a barren vein.
3. Copper veins running east and west; east and west copper lodes.
4. Second system of copper veins, orcontracopper lodes.
5. Crossing veins; cross courses.
6. Modern copper veins; more recent copper lodes.
7. Clay veins; of which there are two sets, the more ancient, calledCross-Fluckans; and the more modern, calledSlides.
There are therefore three systems of copper veins in Cornwall; of which the first is considered to be the most ancient, because it is always traversed by the two others, and because, on the contrary, it never cuts them off. The width of these veins does not exceed 6 feet, though occasional enlargements to the extent of 12 feet sometimes take place. Their length is unknown, but the one explored in theUnited Mineshas been traced over an extent of seven miles. The gangue of these veins is generally quartz, either pure, or mixed with green particles analogous to chlorite. They contain iron pyrites, blende, sulphuret, and several other compounds of copper, such as the carbonate, phosphate, arseniate, muriate, &c. The most part of the copper veins are accompanied with small argillaceous veins, called by the minersfluckan of the lode. These are often found upon both sides of the vein, so as to form cheeks orsalebandes.
When two veins intersect each other, the direction of the one thrown out becomes an object of interest to the miner and geologist. In Saxony it is regarded as a general fact that the rejected portion is always to the side of theobtuse angle; this also holds generally in Cornwall, and the more obtuse the angle of incidence, the more considerable the out-throw.
The great copper vein ofCarharack, in the parish of Gwenap, is a most instructive example of intersection. The power of this vein is 8 feet; it runs nearly from east to west, and dips towards the north at an inclination of 2 feet in a fathom. Its upper part is in the killas, its lower part in the granite. The vein has suffered two intersections; the first results from encountering the vein calledSteven’s fluckan, which runs from north-east to south-west, throwing it out several fathoms. The second has been caused by another vein, almost at right angles to the first, and which has driven it 20 fathoms out to the right side. The fall of the vein occurs, therefore, in one case to the right, and in the other to the left; but in both instances, it is to the side of the obtuse angle. This disposition is very singular; for one portion of the vein appears to have ascended, while another has sunk.
The mining works in the copper veins are carried on by reverse steps; seeMines. The grand shafts for drainage and extraction are vertical, and open upon the roof side of the vein, traversing it to a certain depth. These pits are sunk to the lowest point of the exploration; and, in proportion as the workings descend, by means of excavations in the vein, the pits are deepened and put into communication towards their bottom witheach new gallery of elongation, by means of transverse galleries. At present, the main shafts are fully 160 fathoms deep. Their horizontal section is oblong, and is divided into two compartments; the one destined for extraction, the other for the pumps. Their timbering has nothing remarkable, but is executed with every attention to economy, the whole wood employed in these mines being brought from Norway.
The descent of the workmen is effected by inclined shafts scooped out of the vein; the ladders are slightly inclined; they are interrupted every 10 fathoms by floors; the steps are made of iron, and, to prevent them from turning under the foot, the form of a miner’s punch or jumper has been given them, the one end being round, and the other being wedge-shaped.
The ore is raised either by means of horse-gins, or by steam-engine power most frequently of high pressure. I shall take theConsolidated Minesas an example.
The draining, which is one of the most considerable sources of expense, both from the quantity of water, and from the depth of the mine, is executed by means of sucking and forcing pumps, the whole piston-rods of which, 120 feet long, are attached to a main-rod suspended at the extremity of the working beam of a steam-engine.
On this mine three steam-engines are erected of very great power, for the purpose of drainage; the one called theMariaengine is of the first-rate force, and most improved construction. The cylinder is 90 inches in internal diameter, and the length of the stroke is 9 feet 11 inches. It works single stroke, and is encased in a coating of bricks to prevent dissipation of the heat. The vapour is admitted at the upper end of the cylinder during the commencement of the fall of the piston, at a pressure capable of forming an equilibrium with a column of 60 inches of mercury. The introduction of the steam ceases whenever the piston has descended through a certain space, which may be increased or diminished at pleasure. During the remainder of the descent the piston is pressed merely by this vapour in its progressive expansion, while the under side of the piston communicates with the condenser. It ascends by the counterweight at the pump end of the working beam. Hence, it is only during the descent of the piston, that the effective stroke is exerted. Frequently the steam is admitted only during the sixth part of the course of the piston, or 18 inches. In this way the power of the engine is proportioned to the work to be done; that is, to the body of water to be raised. Themaximumforce of the above engine is about 310 horses; though it is often made to act with only one third of this power.
The copper mines of the isle of Anglesey, those of North Wales, of Westmoreland, the adjacent parts of Lancashire and Cumberland, of the south west of Scotland, of the Isle of Man, and of the south east of Ireland, occur also in primitive or transition rocks. The ores lie sometimes in masses, but more frequently in veins. The mine of Ecton in Staffordshire, and that of Cross-gill-burn, near Alston-moor in Cumberland, occur in transition or metalliferous limestone.
The copper ores extracted both from the granitic and schistose localities, as well as from the calcareous, are uniformly copper pyrites more or less mixed with iron pyrites; the red oxide, carbonate, arseniate, phosphate, and muriate of copper, are very rare in these districts.
The working of copper in the isle of Anglesey may be traced to a very remote era. It appears that the Romans were acquainted with the Hamlet mine near Holyhead; but it was worked with little activity till about 70 years ago. This metalliferous deposit lies in a greenish clay slate, passing into talc slate; a rock associated with serpentine and euphotide (gabbroof Von Buch). The veins of copper are from one to two yards thick; and they converge towards a point where their union forms a considerable mass of ore. On this mass the mine was first pierced by an open excavation, which is now upwards of 300 feet deep, and appears from above like a vast funnel. Galleries are formed at different levels upon the flank of the excavation to follow the several small veins, which run in all directions, and diverge from a common centre like so many radii. The ore receives in these galleries a kind of sorting, and is raised by means of hand windlasses, to the summit of a hill, where it is cleaned by breaking and riddling.
The water is so scanty in this mine that it is pumped up by a six-horse steam-engine. A great proportion of it is charged with sulphate of copper. It is conveyed into reservoirs containing pieces of old iron; the sulphate is thus decomposed into copper of cementation. The Anglesea ore is poor, yielding only from 2 to 3per cent.of copper: a portion of its sulphur is collected in roasting the ore.
Mechanical preparation of the copper ores in Cornwall.—The ore receives a first sorting, either within the mine itself, or at its mouth, the object of which is to separate all the pieces larger than a walnut. These are then reduced by the hammer to a smaller size; after which the whole are sorted into four lots, according to their relative richness. The fragments of poor ore are pounded in the stamps so that the metallic portion may be separated by washing.
The rich ore is broken into small bits, of the size of a nut, with a flat beater, formedof a piece of iron 6 inches square and 1 inch thick, adapted to a wooden handle. The ore to be broken is placed upon plates of cast-iron; each about 16 inches square and 11⁄2inch thick. These iron plates are set towards the edge of a small mound about a yard high, constructed with dry stones rammed with earth. The upper surface of this mound is a little inclined from behind forwards. The work is performed by women, each furnished with a beater; the ore is placed in front of them beyond the plates; they break it, and strew it at their feet, whence it is lifted and disposed of to the smelting-houses.
Inferior ores, containing a notable proportion of stony matters, are also broken with the beater, and the rich parts are separated by riddling and washing from the useless matters.
The smaller ore is washed on a sieve by shaking it in a stream of water, which carries away the lighter stony pieces, and leaves the denser metalliferous. They are then sorted by hand. Thus by beating, stamping, and riddling in water, the stony substances are in a great measure separated. The finer ground matter is washed on a plane table, over which a current of water is made to flow. Finally, the ore nearly fine is put into a large tub with water, and briskly stirred about with a shovel, after which it settles in the order of richness, the pure metallic ore being nearest the bottom. The stamps used for copper ore in Cornwall are the same as those used for tin ores, of which we shall speak in treating of the latter metal, as well as of the boxes for washing the fine powder orslime. These in fact do not differ essentially from the stamping mills and washing apparatus described in the articleMetallurgy. Crushing rolls are of late years much employed. SeeLeadandTin.
Cornwall being destitute of coal, the whole copper ore which this county produces is sent for smelting to South Wales. Here are 15 copper works upon the Swansea and Neath, which pursue a nearly uniform and much improved process, consisting in a series of calcinations, fusions, and roastings, executed upon the ores and the matters resulting from them.
The furnaces are of the reverberatory construction; they vary in their dimensions and in the number of their openings, according to the operations for which they were intended. There are 5 of them:—1. The calcining furnace or calciner; 2. The melting furnace; 3. The roasting furnace or roaster; 4. The refining furnace; 5. The heating or igniting furnace.
Calcining furnace
1. The calcining furnace rests upon a vault,C, into which the ore is raked down after being calcined; it is built of bricks, and bound with iron bars, as shown in the elevation,fig.296.The hearth,B B,figs.296.and298.is placed upon a level with the lower horizontal binding bar, and has nearly the form of an ellipse, truncated at the two extremities of its great axis. It is horizontal, bedded with fire-bricks set on edge, so that it may be removed and repaired without disturbing the arch upon which it reposes. Holes, not visible in the figure, are left in the shelves before each door,c c, through which the roasted ore is let fall into the subjacent vault. The dimensions of the hearthB Bare immense, being from 17 to 19 feet in length, and from 14 to 16 in breadth. The fire-place,A,fig.298., is from 41⁄2to 5 feet long, and 3 feet wide. The bridge or low wall,b,fig.302., which separates the fire-place from the hearth, is 2 feet thick; and in Mr. Vivian’s smelting-works is hollow, as shown in the figure, and communicates at its two ends with the atmosphere, in order to conduct a supply of fresh air to the hearth of the furnace. This judicious contrivance will be described in explaining theroastingoperation. The arched roof of the furnace slopes down from the bridge to the beginning of the chimney,f,fig.296,298., its height above the hearth being at the first point about 26 inches, and from 8 to 12 at the second.
Such great calcining furnaces have 4 or 5 doors,c c c c,fig.298., one for the fire-place, as shown at the right hand infig.297., and 3 or 4 others for working the ore upon thereverberatory hearth. If there be 3, 2 of them are placed between the vertical binding bars upon one side, and a third upon the opposite side of the furnace; if there be 4, 2 are placed upon each side, facing one another. These openings are 12 inches square, and are bound with iron frames. The chimney is about 22 feet high, and is placed at one angle of the hearth, as atf,fig.298., being joined by an inclined flue to the furnace.
For charging it with ore there is usually placed above the upper part of the vault 2 hoppers,E E, in a line with the doors; they are formed of 4 plates of iron, supported in an iron frame. Beneath each of them there is an orifice for letting the ore down into the hearth.
These furnaces serve for calcining the ore, and themattsorcrude coppers: for the latter purpose, indeed, furnaces of two stories are sometimes employed, as represented infig.301.The dimensions of each floor in this case are a little less than the preceding. Two doors,c c, correspond to each hearth, and the workmen, while employed at the upper story, stand upon a raised movable platform.
Melting furnace
2.Melting furnace,figs.299and300.—The form of the hearth is also elliptical, but the dimensions are smaller than in the calcining furnace. The length does not exceed 11 or 111⁄2feet, and the breadth varies from 7 to 8. The fire-place is however larger in proportion, its length being from 31⁄2feet to 4, and its breadth from 3 to 31⁄2; this size being requisite to produce the higher temperature of this furnace. It has fewer openings, there being commonly three; one to the fire-place atD, a second one,O, in the side, kept generally shut, and used only when incrustations need to be scraped off the hearth, or when the furnace is to be entered for repairs; and the third or working-door,G, placed on the front of the furnace beneath the chimney. Through it the scoriæ are raked out, and the melted matters are stirred and puddled, &c.
The hearth is bedded with infusible sand, and slopes slightly towards the side door, to facilitate the discharge of the metal. Above this door there is a hole in the wall of the chimney (fig.300.) for letting the metal escape. An iron gutter,O, leads it into a pit,K, bottomed with an iron receiving-pot, which may be lifted out by a crane. The pitMis filled with water, and the metal becomes granulated as it falls into the receiver. The melting furnaces are surmounted by a hopper,L, as shown infig.299.
Melting cum calcination furnace
Melting furnaces are sometimes used also for calcination. There are some such near Swansea, which serve this double purpose; they are composed of 3 floors (fig.301.) The floorAis destined for melting the calcined ore; the other two,B C, serve for calcination. The heat being less powerful, upon the upper soleC, the ore gets dried upon it, and begins to be calcined—a process completed on the next floor. Square holes,d, left in the hearthsBandC, put them in communication with each other, and with the lower oneA; these perforations are shut during the operation by a sheet of iron, removable at pleasure.
The hearthsbandcare made of bricks; they are horizontal at top and slightly vaulted beneath; they are 2 bricks thick, and their dimensions are larger than those of the inferior hearths, as they extend above the fire-place. On the floors destined for calcination the furnace has two doors on one of its sides: on the lower story there are also two; but they are differently collocated. The first, being in the front of the furnace, serves for drawing off the scoriæ, for working the metal, &c.; and the second, upon the side, admits workmen to make necessary repairs. Below this door the discharge or tap-holeAis placed, which communicates by a cast-iron gutter with a pit filled with water. The dimensions of this furnace in length and breadth are nearly the same as those of the melting furnace above described; the total height is nearly 12 feet. It is charged by means of one or two hoppers.
3.Roasting furnace.—The furnaces employed for this purpose are in general analogous to the calcining ones; but in the smelting works of Hafod, the property of Messrs. Vivian, these furnaces, alluded to above, present a peculiar construction, for the purpose of introducing a continuous current of air upon the metal, in order to facilitate its oxidizement. This process was originally invented by Mr. Sheffield, who disposed of his patent right to Messrs. Vivian.
Bridge between hearth and fire-place
The air is admitted by a channel,c c, through the middle of the fire-bridge,fig.302, and extending all its length; it communicates with the atmosphere at its two endsc c; square holes,b b, left at right angles to this channel, conduct the air into the furnace.This very simple construction produces a powerful effect in the roasting operation. It not only promotes the oxidizement of the metals, but burns the smoke, and assists in the vaporisation of the sulphur; while by keeping the bridge cool it preserves it from wasting, and secures uniformity of temperature to the hearth.
4.Refining furnace.—In this, as in the melting furnace, the sole slopes towards the door in front, instead of towards the side doors, because in the refining furnace the copper collects into a cavity formed in the hearth towards the front door, from which it is lifted out by ladles; whereas, in the melting furnaces, the metal is run out by a tap-hole in the side. The hearth sole is laid with sand; but the roof is higher than in the melting furnace, being from 32 to 36 inches. If the top arch were too much depressed, there might be produced upon the surface of the metal a layer of oxide very prejudicial to the quality of the copper. When the metal in that case is run out, its surface solidifies and cracks, while the melted copper beneath breaks through and spreads irregularly over the cake. This accident, called therising of the copper, hinders it from being laminated, and requires it to be exposed to a fresh refining process, when lead must be added to dissolve the oxide of copper. This is the only occasion upon which the addition of lead is proper in refining copper. When the metal to be refined is mixed with others, particularly with tin, as in extracting copper from old bells, then very wide furnaces must be employed, to expose the metallic bath upon a great surface, and in a thin stratum, to the oxidizing action of the air.
The doorG,fig.300., upon the side of the refining furnace, is very large, and is shut with a framed brick door, balanced by a counter-weight. This door being open during the refining process, the heat is stronger atBthan atA(figs.299,300.)
5.Heating furnaces, being destined to heat the pigs or bars of copper to be laminated, as well as the copper sheets themselves, are made much longer in proportion to their breadth. Their hearth is horizontal, the vault not much depressed; they have only one door, placed upon the side, but which extends nearly the whole length of the furnace: this door may be raised by means of a counter-weight, in the same way as in the furnaces for the fabrication of sheet-iron and brass.
Series of operations to which the ore is subjected.—The ores which are smelted in the Swansea works are cupreous pyrites, more or less mingled withgangue(vein-stone). The pyrites is composed of nearly equal proportions of sulphuret of copper and sulphuret of iron.
The earthy matters which accompany the pyrites are usually siliceous, though in some mines the metalliferous deposit is mixed with clay or fluate of lime. Along with these substances, pretty uniformly distributed, tin and arsenical pyrites occur occasionally with the copper; and though these two metals are not chemically combined, yet they cannot be separated entirely in the mechanical preparations. The constituent parts of the ore prepared for smelting are, therefore, copper, iron, sulphur, with tin, arsenic, and earthy matters in some cases. The different ores are mixed in such proportions that the average metallic contents may amount to 81⁄2per cent. The smelting process consists in alternate roastings and fusions. The following description of it is chiefly taken from an excellent paper, published by John Vivian, esq., in the Annals of Philosophy for 1823.
In the roasting operation the volatile substances are disengaged mostly in the gaseous state, while the metals that possess a strong affinity for oxygen become oxidized. In the fusion the earthy substances combine with these oxides, and form glassy scoriæ or slags, which float upon the surface of the melted metal.
These calcinations and fusions take place in the following order:—
1. Calcination of the ore. 2. Melting of the calcined ore. 3. Calcination of the coarse metal. 4. Melting of the calcined coarse metal. 5. Calcination of the fine metal (second matt). 6. Melting of the calcined fine metal. 7. Roasting of the coarse copper. In some smelting works, this roasting is repeated four times; in which case a calcination and a melting are omitted. In the Havod works, however, the same saving is made without increasing the number of roastings. 8. Refining or toughening the copper.
Besides these operations, which constitute the treatment of copper properly speaking, two others are sometimes performed, in which only the scoriæ are melted. These may be designated by the lettersaandb.ais the re-melting of the portion of the scoriæ of the second process, which contain some metallic granulations.bis a particular melting of the scoriæ of the fourth operation. This fusion is intended to concentrate the particles of copper in the scoriæ, and is not practised in all smelting works.
First operation. Calcination of the ore.—The different ores, on arriving from Cornwall and other districts where they are mined, are discharged in continuous cargoes at the smelting works, in such a way, that by taking out a portion from several heaps at a time, a tolerably uniform mixture of ores is obtained; which is very essential in a foundry, because, the ores being different in qualities and contents, they act asfluxes upon each other. The ore thus mixed is transported to the works in wooden measures that hold a hundred-weight. The workmen entrusted with the calcination convey the ore into the hoppers of the calcining furnace, whence it falls into the hearth; other workmen spread it uniformly on the surface by iron rakes. The charge of a furnace is from three tons to three tons and a half. Fire is applied and gradually increased, till, towards the end of the operation, the temperature be as high as the ore can support without melting or agglutinating. To prevent this running together, and to aid the extrication of the sulphur, the surfaces are renewed, by stirring up the ore at the end of every hour. The calcination is usually completed at the end of 12 hours, when the ore is tumbled into the arch under the sole of the furnace. Whenever the ore is cold enough to be moved, it is taken out of the arch, and conveyed to the calcined heap.
The ore in this process hardly changes weight, having gained in oxidizement nearly as much as it has lost in sulphur and arsenic; and if the roasting has been rightly managed, the ore is in a black powder, owing to the oxide of iron present.
Second operation. Fusion of the calcined ore.—The calcined ore is likewise given to the melters in measures containing a hundred-weight. They toss it into hoppers, and after it has fallen on the hearth, they spread it uniformly. They then let down the door, and lute it tightly. In this fusion there are added about 2 cwt. of scoriæ proceeding from the melting of the calcined matt, to be afterwards described. The object of this addition is not only to extract the copper that these scoriæ may contain, but especially to increase the fusibility of the mixture. Sometimes also, when the composition of the ore requires it, lime, sand, or fluor spar is added; and particularly the last fluxing article.
The furnace being charged, fire is applied, and the sole care of the founder is to keep up the heat so as to have a perfect fusion; the workman then opens the door, and stirs about the liquid mass to complete the separation of the metal (or rather of the matt) from the scoriæ, as well as to hinder the melted matter from sticking to the sole. The furnace being ready, that is, the fusion being perfect, the founder takes out the scoriæ by the front door, by means of a rake. When the matt is thus freed from the scoriæ, a second charge of calcined ore is then introduced to increase the metallic bath; which second fusion is executed like the first. In this way, new charges of roasted ore are put in till the matt collected on the hearth rises to a level with the door-way, which happens commonly after the third charge. The tap hole is now opened; the matt flows out into the pit filled with water, where it is granulated during its immersion; and it collects in the pan placed at the bottom. The granulated matt is next conveyed into the matt warehouse. The oxidation with which the grains get covered by the action of the water, does not allow the proper colour of the matt or coarse metal to be distinguished; but in the bits which stick in the gutter, it is seen to be of a steel gray. Its fracture is compact, and its lustre metallic. The scoriæ often contain metallic grains; they are broken and picked with care. All the portions which include some metallic particles are re-melted in an accessory process. The rejected scoriæ have been found to be composed of siliceous matter 59, oxide of copper 1, oxide of tin 0·7.
In this operation, the copper is concentrated by the separation of a great part of the matters with which it was mixed or combined. The granulated matt produced, contains in general 33 per cent. of copper; it is therefore four times richer than the ore; and its mass is consequently diminished in that proportion. The constituent parts are principally copper, iron, and sulphur.
The most important point to hit in the fusion just described, is to make a fusible mixture of the earths and the oxides, so that the matt of copper may, in virtue of its greater specific gravity, fall to the under-part, and separate exactly from the slag. This point is attained by means of the metallic oxides contained in the scoriæ of the fourth operation, of which 2 cwt. were added to the charge. These consist almost entirely of black oxide of iron. When the ores are very difficult to melt, a measure of about half a hundred-weight of fluor spar is added; but this must be done with precaution, for fear of increasing the scoriæ too much.
The business goes on day and night. Five charges are commonly put through hands in the course of 24 hours; but when all circumstances are favourable, that is to say, when the ore is fusible, when the fuel is of the first quality, and when the furnace is in good condition, even six charges a day have been despatched.
The charge is a ton and a half of calcined ore, so that a melting furnace corresponds nearly to a calcining furnace; the latter turning out nearly 7 tons of calcined ore in 24 hours.
The workmen are paid by the ton.
Third operation. Calcination of the coarse metal, or the matt.—The object of this operation is principally to oxidize the iron, an oxidation easier to execute, than in the firstcalcining, because the metal is now disengaged from the earthy substances, which screened it from the action of the air.
This calcination is executed in the furnace already represented,fig.296,297,298.page 318.exactly in the same way as the ore was calcined. The metal must be perpetually stirred about, to expose all its surfaces to the action of the hot air, and to hinder the clotting together. The operation lasts 24 hours; during the first six, the fire should be very moderate, and thereafter gradually increased to the end of the calcination. The charge is, like that of the first, 3 tons and a half.
Fourth operation. Melting of the calcined coarse metal, or calcined matt.—In the fusion of this first calcined matt, some scoriæ of the latter operations must be added, which are very rich in oxide of copper, and some crusts from the hearth, which are likewise impregnated with it. The proportion of these substances varies according to the quality of the calcined matt.
In this second fusion, the oxide of copper contained in the scoriæ, is reduced by the affinity of the sulphur, one portion of which passes to the state of acid, while the other forms a subsulphuret with the copper become free. The matt commonly contains a sufficient quantity of sulphur to reduce the oxide of copper completely; but if not, which may happen if the calcination of the matt has been pushed too far, a small quantity of uncalcined matt must be introduced, which, by furnishing sulphur, diminishes the richness of the scoriæ, and facilitates the fusion.
The scoriæ are taken out by the front door, by drawing them forward with a rake. They have a great specific gravity; are brilliant with metallic lustre, very crystalline, and present, in the cavities, crystals like those of pyroxene; they break easily into very sharp-edged fragments. They contain no granulated metal in the interior; but it sometimes occurs, on account of the small thicknesses of the stratum of scoriæ, that these carry off with them, when they are withdrawn, some metallic particles.
These scoriæ, as we have already stated, under the fusion of the roasted ore, are in general melted with it. In some cases, however, a special melting is assigned to them.
The matt obtained in this second fusion is either run out into water like the first, or moulded into pigs (ingots), according to the mode of treatment which it is to undergo. This matt, called by the smeltersfine metalwhen it is granulated, andblue metalwhen it is in pigs, is of a light grey colour, compact, and bluish at the surface. It is collected in the first form when it is to be calcined anew; and in the second, when it must immediately undergo the operation ofroasting. Its contents in copper are 60per cent.This operation, which is but sometimes had recourse to, lasts 5 or 6 hours. The charge is 1 ton.
(b)Particular fusion of the scoriæ of the fourth operation.—In re-melting these scoriæ, the object is to procure the copper which they contain. To effect this fusion, the scoriæ are mixed with pulverized coal, or other carbonaceous matters. The copper and several other metals are deoxidized, and furnish a white and brittle alloy. The scoriæ resulting from this melting are in part employed in the first melting, and in part thrown away. They are crystalline, and present crystals often in the cavities, which appear to belong to bisilicate of iron. They have a metallic lustre, and break into very sharp-edged fragments. The white metal is melted again, and then united to the product of the second fusion.
Fifth operation. Calcination of the second matt, or fine metal of the smelter.—This is executed in precisely the same way as that of the first matt. It lasts 24 hours; and the charge is usually 3 tons.
Sixth operation. Melting of the calcined fine metal.—This fusion is conducted like that of the first matt. The black copper, or coarse copper, which it produces, contains from 70 to 80 per cent. of pure metal; it is run into ingots, in order to undergo the operation of roasting.
The scoriæ are rich in copper; they are added to the fusion of the calcined coarse metal of the fourth operation.
In the smelting houses of Messrs. Vivian, at Hafod, near Swansea, the fifth and sixth operations have been omitted of late years. The second matt is run into pigs, under the name ofblue metal, to be immediately exposed to the roasting.
The disposition of the canalaa′,fig.302., which introduces a continuous current of air to the hearth of the furnace, accelerates and facilitates the calcination of the matt; an advantage which has simplified the treatment, by diminishing the number of calculations.
Seventh operation. Roasting of the coarse copper, the product of the sixth operation.The chief object of this operation is oxidizement; it is performed either in an ordinary roasting furnace, or in the one belonging tofig.302., which admits a constant current of air. The pigs of metal derived from the preceding melting are exposed, on the hearth of the furnace, to the action of the air, which oxidizes the iron and other foreign metals with which the copper is still contaminated. The duration of the roasting varies from12 to 24 hours, according to the degree of purity of the crude copper. The temperature should be graduated, in order that the oxidizement may have time to complete, and that the volatile substances which the copper still retains may escape in the gaseous form. The fusion must take place only towards the end of the operation.
The charge varies from a ton and a quarter to a ton and a half. The metal obtained is run out into moulds of sand. It is covered with black blisters, like steel of cementation; whence it has got the name of blistered copper. In the interior of these pigs, the copper presents a porous texture, occasioned by the ebullition produced by the escape of the gases during the moulding. The copper being now almost entirely purged from the sulphur, iron, and the other substances with which it was combined, is in a fit state to be refined. This operation affords some scoriæ; they are very heavy, and contain a great deal of oxide of copper, sometimes even metallic copper.
These scoriæ, as well as those of the third melting and of the refining, are added to the second fusion, as we have already stated, in describing the fourth operation.
In some works, the roasting is repeated several times upon theblue metal, in order to bring it to a state fit for refining. We shall afterwards notice this modification of the treatment.
Eighth operation. Refining or toughening.—The pigs of copper intended for refining are put upon the sole of the refining furnace through the door in the side. A slight heat is first given, to finish the roasting or oxidation, in case this operation has not already been pushed far enough. The fire is to be increased by slow degrees, so that, by the end of 6 hours, the copper may begin to flow. When all the metal is melted, and when the heat is considerable, the workman lifts up the door in the front, and withdraws with a rake the few scoriæ which may cover the copper bath. They are red, lamellated, very heavy, and closely resemble protoxide of copper.
The refiner takes then an assay with a small ladle, and when it cools, breaks it in a vice, to see the state of the copper. From the appearance of the assay, the aspect of the bath, the state of the fire, &c., he judges if he may proceed to the toughening, and what quantity of wooden spars and wood charcoal he must add to render the metal malleable, or, in the language of the smelters, bring it to the proper pitch. When the operation of refining begins, the copper is brittle or dry, and of a deep red colour approaching to purple. Its grain is coarse, open, and somewhat crystalline.
To execute the refining, the surface of the metal is covered over with wood charcoal, and stirred about with a spar or rod of birch wood. The gases which escape from the wood, occasion a brisk effervescence. More wood charcoal is added from time to time, so that the surface of the metal may be always covered with it, and the stirring is continued with the rods, till the operation of refining be finished; a circumstance indicated by the assays taken in succession. The grain of the copper becomes finer and finer, and its colour gradually brightens. When the grain is extremely fine, orclosed, when the trial pieces half cut through and then broken, present a silky fracture, and when the copper is of a fine light red, the refiner considers the operation to be completed; but he verifies still further the purity of the copper, by trying its malleability. For this purpose, he takes out a sample in his small ladle, and pours it into a mould. When the copper is solidified, but still red-hot, he forges it. If it is soft under the hammer, if it does not crack on the edges, the refiner is satisfied with its ductility, and he pronounces it to be in itsproper state. He orders the workmen to mould it; who then lift the copper out of the furnace in large iron ladles lined with clay, and pour it into moulds of the size suitable to the demands of commerce. The ordinary dimensions of the ingots or pigs are 12 inches broad, 18 long, and from 2 to 21⁄2thick.
The period of the refining process is 20 hours. In the first six, the metal heats, and suffers a kind of roasting; at the end of this time it melts. It takes four hours to reach the point at which the refining, properly speaking, begins; and this last part of the process lasts about 4 hours. Finally, 6 hours are required to arrange the moulds, cast the ingots, and let the furnace cool.
The charge of copper in the refining process depends upon the dimensions of the furnace. In the Hafod works, one of the most important in England, the charge varies from 3 to 5 tons; and the quantity of pure copper manufactured in a week is from 40 to 50 tons.
The consumption of fuel is from 15 to 18 parts of coal, for one part of refined copper in pigs.
When the copper offers difficulties in the refining, a few pounds of lead are added to it. This metal, by the facility with which it scorifies, acts as a purifier, aiding the oxidation of the iron and other metals that may be present in the copper. The lead ought to be added immediately after removing the door to skim the surface. The copper should be constantly stirred up, to expose the greatest possible surface to the action of the air, and to produce the complete oxidation of the lead; for the smallest quantity of this metal alloyed in copper, is difficult to clear up in the lamination; that is to say, the scale of oxide does not come cleanly from the surface of the sheets.
The operation of refining copper is delicate, and requires, upon the part of the workmen, great skill and attention to give the metal its due ductility. Its surface ought to be entirely covered with wood charcoal; without this precaution, the refining of the metal wouldgo back, as the workmen say, during the long interval which elapses in the moulding; whenever this accident happens, the metal must be stirred up anew with the wooden pole.
Too long employment of the wooden rod gives birth to another remarkable accident, for the copper becomes more brittle than it was prior to the commencement of the refining; that is, when it wasdry. Its colour is now of a very brilliant yellowish red, and its fracture is fibrous. When this circumstance occurs, when the refining, as the workmen say, hasgone too far, the refiner removes the charcoal from the top of the melted metal; he opens the side door, to expose the copper to the action of the air, and it then resumes its malleable condition.
Mr. Vivian, to whom we owe the above very graphic account of the processes, has explained, in a very happy manner, the theory of refining. He conceives, we may conclude, that the copper in thedry state, before the refining, is combined with a small portion of oxygen, or, in other words, that a small portion of oxide of copper is diffused through the mass, or combined with it; and that this proportion of oxygen is expelled by the deoxidizing action of the wood and charcoal, whereby the metal becomes malleable. 2. That when the refining process is carried too far, the copper gets combined with a little charcoal. Thus copper, like iron, is brittle when combined with oxygen and charcoal; and becomes malleable only when freed entirely from these two substances.
It is remarkable, that copper, in thedry state, has a very strong action upon iron; and that the tools employed in stirring the liquid metal become very glistening, like those used in a farrier’s forge. The iron of the tools consumes more rapidly at that time, than when the copper has acquired its malleable state. The metal requires, also, whendry, more time to become solid, or to cool, than when it is refined; a circumstance depending, probably, upon the difference in fusibility of the copper in the two states, and which seems to indicate, as in the case of iron, the presence of oxygen.
When the proper refining point has been passed, another very remarkable circumstance has been observed; namely, that the surface of the copper oxidizes more difficultly, and that it is uncommonly brilliant; reflecting clearly the bricks of the furnace vault. This fact is favourable to the idea suggested above, that the metal is in that case combined with a small quantity of carbon; which absorbs the oxygen of the air, and thus protects the metal from its action.
Copper is brought into the market in different forms, according to the purposes which it is to serve. What is to be employed in the manufacture of brass is granulated. In this condition it presents more surface to the action of zinc or calamine, and combines with it more readily. To produce this granulation, the metal is poured into a large ladle, pierced with holes, and placed above a cistern filled with water, which must be hot or cold, according to the form wished in the grains. When it is hot, round grains are obtained analogous to lead shot; and the copper in this state is calledbean shot. When the melted copper falls into cold water perpetually renewed, the granulations are irregular, thin, and ramified; constitutingfeathered shot. Thebean shotis the form employed in brass making.
Copper is also made into small ingots, about 6 ounces in weight. These are intended for exportation to the East Indies, and are known in commerce by the name of Japan copper. Whenever these little pieces are solidified, they are thrown, while hot, into cold water. This immersion slightly oxidizes the surface of the copper, and gives it a fine red colour.
Lastly, the copper is often reduced into sheets, for the sheathing of ships, and many other purposes. The Hafod works possess a powerful rolling mill, composed of four pairs of cylinders. It is moved by a steam engine, whose cylinder has 40 inches diameter. See the representation of therolling millof the Royal Mint, underGold.
The cylinders for rolling copper into sheets are usually 3 feet long, and 15 inches in diameter. They are uniform. The upper roller may be approached to the under one, by a screw, so that the cylinders are brought closer, as the sheet is to be made thinner.
The ingots of copper are laid upon the sole of a reverberatory furnace to be heated; they are placed alongside each other, and they are formed into piles in a cross-like arrangement, so that the hot air may pass freely round them all. The door of the furnace is shut, and the workman looks in through a peep-hole from time to time, to see if they have taken the requisite temperature; namely, a dull red. The copper is now passed between the cylinders; but although this metal be very malleable, the ingots cannot be reduced to sheets without being several times heated; because the copper cools, and acquires, by compression, a texture which stops the progress of the lamination.
These successive heatings are given in the furnace indicated above; though, when thesheets are to have a very great size, furnaces somewhat different are had recourse to. They are from 12 to 15 feet long, and 5 wide. SeeBrass.
The copper, by successive heating and lamination, gets covered with a coat of oxide, which is removed by steeping the sheets for a few days in a pit filled with urine; they are then put upon the sole of the heating furnace. Ammonia is formed, which acts on the copper oxide, and lays bare the metallic surface. The sheets are next rubbed with a piece of wood, then plunged, while still hot, into water, to make the oxide scale off; and lastly, they are passed cold through the rolling press to smooth them. They are now cut square, and packed up for home sale or exportation.
The following estimate has been given by MM. Dufrénoy and Elie de Beaumont of the expense of manufacturing a ton of copper in South Wales.
The exhalations from the copper smelting works are very detrimental to both vegetable and animal life. They consist of sulphurous acid, sulphuric acid, arsenic and arsenious acids, various gases and fluoric vapours, with solid particles mechanically swept away into the air, besides the coal smoke. Mr. Vivian has invented a very ingenious method of passing the exhalations from the calcining ores andmattsalong horizontal flues or rather galleries of great dimensions, with many crossings and windings of the current, and exposure during the greater part of the circuit to copious showers of cold water. By this simple and powerful system of condensation, the arsenic is deposited in the bottoms of the flues, the sulphurous acid is in a great measure absorbed, and the nuisance is remarkably abated.
The following figures represent certain modifications of the copper calcining and smelting copper furnaces of Swansea.