Sulfuric Acid and Phosphate Industries at Anaconda Reduction Works

DURING the early years of the present century a notable interest appeared in American industry in the matter of recovering and render-ing profitable byproducts of manufacturing operations. Among the byproducts of reduction of sulfide ores in many plants large amounts of sulfur dioxide gas were available. In certain instances the concentration of SO2 in the gases evolved was, or could be made, sufficient to make them suitable for manufacturing sulfuric acid. At the Anaconda Reduction works such a condition existed. Large tonnages of copper concentrate were being roasted and the roaster gases were available and suitable as a source of sulfuric acid. Earlier work on a large scale at Martinez, Calif., and in the Ducktown region, Tennessee, had shown the feasibility of manufacturing sulfuric acid from the SO2 contained in gases arising from the reduction of copper sulfide ores. In California and Tennessee the acid found a ready market in manufacture of fertilizers, while the situation regarding disposal of the sulfuric acid was quite different at Anaconda. No local use for acid existed, and a commodity of such low value could not stand freight charges to consuming centers. There was a very large accumulation of sand tailings from the gravity concentration mill below the plant at Anaconda. This material, made by the comparatively crude methods in use up to about 1915, contained about 13 lb. of copper per ton, largely as sulfide minerals. In 1912 serious research work toward recovery of this copper was instituted and after about two years of laboratory and pilot-plant development, a process for accomplishing it was perfected. This process involved roast-ing the sand tailings, leaching the roasted tailings with sulfuric acid, and throwing out the copper by passing the solutions over scrap iron. Under this plan each ton of sand required the introduction of about 70 lb. of 60° Be. sulfuric acid.