The first of these qualities--the very rich ore--is so valuable as to
render advantageous its direct export in the raw state to the coast for
shipment to Europe. The cost of fuel in Bolivia forms so considerable a
charge in smelting operations, that the cost of freight to Europe on very
rich silver ores works out at a relatively insignificant figure, when
compared with the cost of smelting operations in that country. This rich
ore is consequently selected very carefully, and packed up in tough
rawhide bags, so as to make small compact parcels some 18 in. to 2 ft.
long, and 8 in. to 12 in. thick, each containing about 1 cwt. Two of such
bags form a mule load, slung across the animal's back.
The second and third qualities of ore are taken direct to the smelting
works; and where these are situated at some distance from the mines, as at
Huanchaca and Guadalupe, the transport is effected by means of strong but
lightly built iron carts, specially constructed to meet the heavy wear and
tear consequent upon the rough mountain roads. These two classes of ores
are either treated separately, or mixed together in such proportion as is
found by experience to be most suitable for the smelting process.
On its arrival at the reduction works the ore is taken direct to the stamp
mill. At the Huanchaca works there are sixty-five heads of stamps, each
head weighing about 500 lb., with five heads in each battery, and crushing
about 50 cwt. per head per twenty-four hours. The ore is stamped dry,
without water, requiring no coffers; this is a decided advantage as
regards first cost, owing to the great weight of the coffers, from 2 to 3
tons--a very heavy item when the cost of transport from Europe at about
50_l_. per ton is considered. As fast as the ore is stamped, it is
shoveled out by hand, and thrown upon inclined sieves of forty holes per
lineal inch; the stuff which will not pass through the mesh is returned to
the stamps.
Dry stamping may be said to be almost a necessity in dealing with these
rich silver ores, as with the employment of water there is a great loss of
silver, owing to the finer particles being carried away in suspension, and
thus getting mixed with the slimes, from which it is exceedingly difficult
to recover them, especially in those remote regions where the cost of
maintaining large ore-dressing establishments is very heavy. Dry stamping,
however, presents many serious drawbacks, some of which could probably be
eliminated if they received proper attention. For instance, the very fine
dust, which rises in a dense cloud during the operation of stamping, not
only settles down on all parts of the machinery, interfering with its
proper working, so that some part of the battery is nearly always stopped
for repairs, but is also the cause of serious inconvenience to the
workmen. At the Huanchaca mines, owing to the presence of galena or
sulphide of lead in the ores, this fine dust is of such an injurious
character as not unfrequently to cause the death of the workmen; as a
precautionary measure they are accustomed to stuff cotton wool into their
nostrils. This, however, is only a partial preventive; and the men find
the best method of overcoming the evil effect is to return to their homes
at intervals of a few weeks, their places being taken by others for the
same periods. In dry stamping there is also a considerable loss of silver
in the fine particles of rich ore which are carried away as dust and
irrevocably lost. To prevent this loss, the writer proposed while at
Huanchaca that a chamber should be constructed, into which all the fine
dust might be exhausted or blown by a powerful fan or ventilator.
_Roasting_.--From the stamps the stamped ore is taken in small ore cars to
the roasting furnaces, which are double bedded in design, one hearth being
built immediately above the other. This type of furnace has proved, after
various trials, to be that best suited for the treatment of the Bolivian
silver ores, and is stated to have been found the most economical as
regards consumption of fuel, and to give the least trouble in labor.
At the Huanchaca mines these furnaces cost about 100_l_. each, and are
capable of roasting from 2 to 2½ tons of ore in twenty-four hours, the
quantity and cost of the fuel consumed being as follows:
Bolivian dollars at 3s. 1d.
Tola (a kind of shrub), 3 cwt., at 60 cents. 1.80
Yareta (a resinous moss), 4 cwt., at 80 cents. 3.20
Torba (turf), 10 cwt., at 40 cents. 4.00
----
Bolivian dollars. 9.00, say 28s.
One man can attend to two furnaces, and earns 3s. per shift of twelve
hours.
Probably no revolving mechanical furnace is suited to the roasting of
these ores, as the operation requires to be carefully and intelligently
watched, for it is essential to the success of the Francke process that
the ores should not be completely or "dead" roasted, inasmuch as certain
salts, prejudicial to the ultimate proper working of the process, are
liable to be formed if the roasting be too protracted. These salts are
mainly due to the presence of antimony, zinc, lead, and arsenic, all of
which are unfavorable to amalgamation.
The ores are roasted with 8 per cent. of salt, or 400 lb. of salt for the
charge of 2½ tons of ore; the salt costs 70 cents, or 2s. 2d. per 100 lb.
So roasted the ores are only partially chlorinized, and their complete
chlorination is effected subsequently, during the process of amalgamation;
the chlorides are thus formed progressively as required, and, in fact, it
would almost appear that the success of the process virtually consists in
obviating the formation of injurious salts. All the sulphide ores in
Bolivia contain sufficient copper to form the quantity of cuprous chloride
requisite for the first stages of roasting, in order to render the silver
contained in the ore thoroughly amenable to subsequent amalgamation.
_Amalgamating_.--From the furnaces the roasted ore is taken in ore cars to
large hoppers or bins situated immediately behind the grinding and
amalgamating vats, locally known as "tinas," into which the ore is run
from the bin through a chute fitted with a regulating slide. The tinas or
amalgamating vats constitute the prominent feature of the Francke process;
they are large wooden vats, shown in Figs. 1 and 2, page 173, from 6 ft.
to 10 ft. in diameter and 5 ft. deep, capacious enough to treat about 2½
tons of ore at a time. Each vat is very strongly constructed, being bound
with thick iron hoops. At the bottom it is fitted with copper plates about
3 in. thick, A in Fig. 1; and at intervals round the sides of the vat are
fixed copper plates, as shown in Figs. 3 and 4, with ribs on their inner
faces, slightly inclined to the horizontal, for promoting a more thorough
mixing. It is considered essential to the success of the process that the
bottom plates should present a clear rubbing surface of at least 10 square
feet.
[Illustration: THE FRANCKE "TINA" PROCESS FOR THE AMALGAMATION OF SILVER
ORES.]
Within the vat, and working on the top of the copper plates, there is a
heavy copper stirrer or muller, B, Figs. 1 and 2, caused to revolve by the
shafting, C, at the rate of 45 revolutions per minute. At Huanchaca this
stirrer has been made with four projecting radial arms, D D, Figs. 1 and
2; but at Guadalupe it is composed of one single bell-shaped piece, Figs.
3 and 4, without any arms, but with slabs like arms fixed on its
underside; and this latter is claimed to be the most effective. The
stirrer can be lifted or depressed in the vat at will by means of a worm
and screw at the top of the driving shaft, Fig. 3.
The bevel gearing is revolved by shafting connected with pulley wheels and
belting, the wheels being 3 ft. and 1½ ft. in diameter, and 6 in. broad.
The driving engine is placed at one end of the building. Each vat requires
from 2½ to 3 horse-power, or in other words, an expenditure of 1
horse-power per ton of ore treated.
At the bottom of the vat, and in front of it, a large wooden stop-cock is
fitted, through which the liquid amalgam is drawn off at the end of the
process into another shallow-bottomed and smaller vat, Figs. 1 and 2.
Directly above this last vat there is a water hose, supplied with a
flexible spout, through which a strong stream of water is directed upon
the amalgam as it issues from the grinding vat, in order to wash off all
impurities.
The following is the mode of working usually employed. The grinding vat or
tina is first charged to about one-fifth of its depth with water and from
6 cwt. to 7 cwt. of common salt. The amount of salt required in the
process depends naturally on the character of the ore to be treated, as
ascertained by actual experiment, and averages from 150 lb. to 300 lb. per
ton of ore. Into this brine a jet of steam is then directed, and the
stirrer is set to work for about half an hour, until the liquid is in a
thoroughly boiling condition, in which state it must be kept until the end
of the process.
As soon as the liquid reaches boiling point, the stamped and roasted ore
is run into the vat, and at the end of another half-hour about 1 cwt. of
mercury is added, further quantities being added as required at different
stages of the process. The stirring is kept up continuously for eight to
twelve hours, according to the character and richness of the ores. At the
end of this time the amalgam is run out through the stop-cock at bottom of
the vat, is washed, and is put into hydraulic presses, by means of which
the mercury is squeezed out, leaving behind a thick, pulpy mass, composed
mainly of silver, and locally termed a "piña," from its resembling in
shape the cone of a pine tree. These piñas are then carefully weighed and
put into a subliming furnace, Figs. 5 and 6, in order to drive off the
rest of the mercury, the silver being subsequently run into bars. About
four ounces of mercury are lost for every pound of silver made.
The actual quantities of mercury to be added in the grinding vat, and the
times of its addition, are based entirely on practical experience of the
process. With ore assaying 150 oz. to 175 oz. of silver to the ton, 75
lb. of mercury are put in at the commencement, another 75 lb. at intervals
during the middle of the process, and finally another lot of 75 lb.
shortly before the termination. When treating "pacos," or earthy chlorides
of silver, assaying only 20 oz. to 30 oz. of silver to the ton, 36 lb. of
mercury is added to 2½ tons of ore at three different stages of the
process as just described.
The _rationale_ of the process therefore appears to be that the
chlorination of the ores is only partially effected during the roasting,
so as to prevent the formation of injurious salts, and is completed in the
vats, in which the chloride of copper is formed progressively as required,
by the gradual grinding away of the copper by friction between the bottom
copper plates and the stirrer; and this chloride subsequently becoming
incorporated with the boiling brine is considered to quicken the action of
the mercury upon the silver.
_Subliming_.--The subliming furnace, shown in Figs. 5 and 6, is a plain
cylindrical chamber, A, about 4 ft. diameter inside and 4½ ft. high, lined
with firebrick, in the center of which is fixed the upright cast-iron
cylinder or retort, C, of 1 ft. diameter, closed at top and open at
bottom. The furnace top is closed by a cast-iron lid, which is lifted off
for charging the fuel. Round the top of the furnace is a tier of radial
outlet holes for the fuel smoke to escape through; and round the bottom is
a corresponding tier of inlet air-holes, through which the fuel is
continually rabbled with poles by hand. The fuel used is llama dung,
costing 80 cents, or 2s. 6d., per 250 lb.; it makes a very excellent fuel
for smelting purposes, smouldering and maintaining steadily the low heat
required for subliming the mercury from the amalgam. Beneath the furnace
is a vault containing a wrought-iron water-tank, B, into which the open
mouth of the retort, C, projects downward and is submerged below the
water. For charging the retort, the water-tank is placed on a trolly; and
standing upright on a stool inside the tank is placed the piña, or conical
mass of silver amalgam, which is held together by being built up on a
core-bar fitted with a series of horizontal disks. The trolly is then run
into the vault, and the water-tank containing the piña is lifted by
screw-jacks, so as to raise the piña into the retort, in which position
the tank is then supported by a cross-beam. The sublimed mercury is
condensed and collected in the water; and on the completion of the process
the tank is lowered, and the spongy or porous cone of silver is withdrawn
from the retort. The subliming furnaces are ranged in a row, and
communicate by lines of rails with the weigh-house.
* * * * *