Colorado Paper - Oxygen and Sulfur in the Melting of Copper Cathodes

The melting of cathode copper, ususally containing 95.98+ per cent. • Cu, would appear to be a simple matter. Owing to the well known affinity of copper for sulfur, however, so much sulfur is absorbed by the copper during the operation that a long and expensive refining process is required to remove it, and the final product is inferior in purity and lower in electrical conductivity than the original cathode copper. The furnace operation, as now conducted, includes the following stages: 1. Charging the cathodes into the furnace. 2. Melting the cathodes. 3. Oxidizing period—saturating the copper with cuprous sub-oxide and bringing the metal to the condition known as "set copper;'' this is now done by blowing air into the molten bath of metal. 4. Reduction period, otherwise known as "poling," whereby the oxygen previously added is removed by covering the molten bath completely with coke or charcoal and introducing large poles of green wood; this reduces the cuprous sub-oxide, bringing the copper to the "tough pitch" stage ready for casting. 5. Casting Period. Many experiments have been made to obviate the long periods of oxidation and subsequent reduction, with no success. While the copper first cast will be good, as indicated by the set surface of the bars, it is impossible to hold it to the "tough pitch" condition, and long before the whole charge has been poured the copper will become "overpoled," entailing numerous difficulties. Sulfur has always been blamed by the furnace men as the reason why this refining process is necessary, yet the literature on the subject does not sufficiently emphasize how small a proportion of sulfur will ruin copper for practical purposes. The sulfur absorbed by copper during the melting period comes from two sources: (1) the sulfate left on the cathode sheets in the tank houses; (2) the fuel. The percentage of sulfates on the cathodes is variable, and depends on the care taken in washing the cathodes after removing