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 LIBRARY 
 
 THE LIBRARY 
 
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 THE UNIVERSITY 
 
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 http://www.archive.org/details/amalgamationatonOOIambrich 
 
jlivIJLIwOJL]sz[jltion: 
 
 AT THE 
 
 Ontario Mill 
 
 coiwIfaeled with 
 
 The RUSSELL PROCESS 
 
 AT THE 
 
 Marsac Mill. 
 
 Comparison with Smelting, 
 
 BY 
 
 W. G.XAMB, 
 
 F^RK Cl^Y, UXAH, 
 Oeoenaber 1, 1802. 
 
 Reprinted, and Extended, from the 
 
 Engineering and Mining JournUi 
 
>b 6H^h 
 
 COIvIFJLniSOK 
 
 BETWEEN THE 
 
 Amalgamation Process at the Ontario Mill 
 
 AND THE 
 
 Russell Process at the Marsac Mill. 
 
 1891-1893. 
 
 By W. G. Lamb, Superintendent of Marsac Leaching Department. 
 
 In a preceding pamphlet by Mr. W. A. Wilson has been 
 given a comparison of Amalgamation at the Ontario, with the 
 Russell procjpss at the Marsac Mill (Daly Mining Co. , Park City, 
 Utah,) for the first three months of 1891. 
 
 The object of the following pages is to continue the com- 
 parison for the whole year, and to present statistics on points 
 not covered in previous publications. 
 
 The Russell process has now been in continuous use at the 
 Marsac for nearly four years, starting Jan. 1, 1889, running con- 
 tinuously during that year in competition with amalgama|;ion, 
 the ore treated being divided between the two processes, and 
 finally superseding amalgamation at the end of that year. 
 
 The amalgamation statistics here given are from the On- 
 tario Mill, located in the same camp. In that mill amalgama- 
 tion has been in continuous use since its start in January, 1877. 
 
 From th^ir long experience with it — fifteen years — the On- 
 tario obtains as good results by this process as are possible. 
 
 As the cost of labor, fuel and supplies are the same for the 
 two mills, a comparison of statistics is of value in determining 
 the general efficiency and economy of the two processes. The 
 
 L3' 
 
2 THE RUSSELL PROCESS. 
 
 figures here given are taken from the books and reports of the 
 two companies, and are published by permission of the 
 managements. 
 
 The properties of the two companies adjoin and are on the 
 same vein. 
 
 The equipment of the two mills and mill men employed, is 
 
 as follows : 
 
 STATEMENT A. 
 
 ONTARIO. MARSAC. 
 
 2 Rock Crushers, 1 Rock Crusher, 
 
 2 Rotary Driers, 2 Rotary Driers, 
 
 40 Ore Stamps, 30 Ore Stamps, 
 10 Salt Stamps, 5 Salt Stamps, 
 
 2 Stetefeldt Furnaces, 1 Stetefeldt Furnace, 
 
 24 Pans, 6 16 ^ft. Ore Vats, 
 
 12 Settlers, 8 9-ft. Precipitating Tanks. 
 
 71 Mill Men. 51 Mill Men. 
 
 The Ontario Mill treats only the ore from the Ontario 
 Mine, and the Marsac only ore from the Daly Mine. 
 
 The analyses and values of the ore treated at the Ontario 
 and Marsac Mills for 1891, are as follows, the samples on which 
 these analyses were made being composed of all the battery 
 samples taken each day during the entire year: 
 
 STATEMENT B. 
 
 ONTARIO. MARSAC. 
 
 Per cent. Per cent. 
 
 Silica 75.0 76.60 
 
 Zinc 5.73 5.30 
 
 Lead 1.80 3.50 
 
 Iron 2.80 1.65 
 
 Sulphur 2.23 0.70 
 
 Lime (CaO.) 1.76 1.32 
 
 Magnesia (Mg O.) - 0.23 trace 
 
 Copper U.29 0.39 
 
 Ozs. Ozs. 
 
 Silver 39.50 39.10 
 
 Gold ($0.91) 0.044 (fO.91) 0.044 
 
 These two ores are practically the same, both in composi- 
 tion and value. 
 
THE RUSSELL PROCESS. * 3 
 
 The statistics which will be here given on the Ontario and 
 Marsac Mills, refer, of course, only to the comparative efficiency 
 of Amalgamation and the Russell process. But the question has 
 been asked w^hy these ores are not sold to the smelters instead of 
 being milled. 
 
 To sell the ore (which is milled at the Marsac) to the 
 smelters would result as follows : 
 
 The expenses of the Daly Mining Co. for the above year 
 (1891) are : 
 
 STATEMENT C. 
 
 Extraction (Mining) $6.52 
 
 Prospecting 1.65 
 
 Hauling to Mill 0.83 
 
 Milling , 6.27 
 
 Sundries 0.96 
 
 Making a total of $16.23 
 
 With the exception of ' ' milling " and ' ' hauling to mill, " 
 these expenses, if the ores w^ere sold to smelters instead of 
 milled, would stiU continue. Deducting these two items, the 
 expenses are $9.13. 
 
 On the other hand, with silver at 83 cents per ounce, and 
 lead at $4. 00, the highest price offered by the Salt Lake, Kan- 
 sas City, Leadville and Denver smelters, for ore of the above 
 analysis, 39.10 ounces per ton in silver and 91 cents gold, is 
 $14.06 f. o. b. at Park City, the seller to pay hauling to sam- 
 pler, and all sampling and shipping charges, amounting to 
 $2.68 net per ton of ore. 
 
 The total expense incurred, therefore, by the Daly Com- 
 pany before the ore can be sold to the Smelters is $11.81 per 
 ton; the price offered being $14.06, there w^ould be a net profit 
 on each ton sold to the smelters of $2. 25. But by milling, after 
 deducting all mining, prospecting, hauling, milhng, sundry and 
 product expenses, the net profit per ton on the same ore 
 is $12.88, making the net difference between smelting 
 and milling $10,63 per ton, or, on 24,214 tons per year, a 
 difference in favor of the latter of $257,394.82. 
 
THE RUSSELL PROCESS. 
 
 To return to the comparison of Ontario and Marsac. 
 following table gives the crushing statistics for 1891 : 
 
 The 
 
 TABL.E I. 
 
 AMOUNT OF ORE, TIME ON BATTERY, MESH OF SCREEN, 
 RATE OF CRUSHING. 
 
 1891. 
 
 MILL. 
 
 Ore 
 
 Time 
 Battery Run 
 
 Mesh of 
 Screen 
 
 Rate of 
 
 Crushing 
 per day 
 
 Rate of 
 
 Crushing 
 
 per stamp 
 
 per day 
 
 Tons 
 
 Days. 
 
 Mesh. 
 
 Tons. 
 
 Tons. 
 
 Oktario, | 
 40 Stamps ( 
 
 Marsac, I 
 30 Stamps f 
 
 25,650 
 24,214 
 
 341.8 
 347.0 
 
 26 
 20 
 
 75.0 
 70.0 
 
 1.87 
 2.33 
 
 The above difference in rate of crushing per stamp is prob- 
 ably not due entirely to difference in mesh of screen, as Ontario 
 ore may not crush as fast as Daly, even in the same battery 
 and with same mesh of screen, owdng to less dryness, or tem- 
 perature, of the ore as it goes to the battery from the dryers. 
 
 Table II — This gives the comparative fineness and baseness 
 of the product for 1891, as shipped from the Ontario and Mar- 
 sac Mills, the product of the Ontario being bars of bullion, and 
 that of the Marsac dried sulphides, the form in which all Mar- 
 sac products were shipped during 1891. 
 
 TABL.E II. 
 
 FINENESS AND BASENESS OF PRODUCT. 
 1891. 
 
 SILVER. 
 
 GOLD. 
 
 COPPER. 
 
 Fineness of Product. 
 
 Fineness of Product. 
 
 Baseness of Product. 
 
 Ontario. 
 
 Marsac. 
 
 Ontario. 
 
 Marsac. 
 
 Ontario. 
 
 Marsac. 
 
 Fine. 
 
 Fine. 
 
 Fine. 
 
 .425 
 
 .313 
 
 .00025 
 
 .00026 
 
 .575 
 
 .153 
 
 The figures given for the Marsac represent the average 
 dried precipitates from the wash water and leaching solutions, 
 excepting the lead carbonate product. 
 
THE RUSSELL PROCESS. 5 
 
 The distribution of the silver in the products for 1891 was 
 
 as follows: 
 
 STATEMENT D. 
 
 Base Sulphides— from Wash Water 11.63 per cent. 
 
 Regular '* — Ordinary and Extra Solution 85.55 per cent. 
 
 Lead Carbonate *' " " 1.71 per cent, 
 
 Mill Cleanings— under filters and in launders 1.11 per cent. 
 
 The large amount, 1 1.63 per cent, of silver product as wash 
 water precipitate, is caused by precipitating the weak hyposul- 
 phite solution in same tanks with the wash water. 
 
 The wash water product assays per ton 3957.0 ozs. silver 
 and ;^ 5 8. 44 gold. The regular sulphides from leaching solutions 
 assay from 7150.0 ozs. to 1 1420.0 ozs. — averaging 9815.0 ozs. 
 silver per ton for year 1891, and ;^i 87. 00 gold. 
 
 During the present year, 1892, all the lead has been pre- 
 cipitated by soda ash, making the average value of regular sul- 
 phides in silver 1 1527.0 ozs., and ^246.00 in gold, or again of 
 1 7/4 P^^ cent, in fineness of sulphides, due to the precipita- 
 tion of the lead by itself by soda ash. For reasons connected with 
 the chemical reactions in the refining of the product, also, it is 
 essential that lead should be kept out of the sulphides, thus 
 necessitating the use of soda ash as a precipitant for the lead. 
 
 An analysis, by Stallman, of an average lot of dried sul- 
 phides, is as follows : 
 
 Copper 21.60 per cent. 
 
 Sulphur : 24.83 
 
 Iron 0.75 
 
 Alumina 0.25 " 
 
 Arsenic trace 
 
 Antimony 0.18 per cent. 
 
 Silica 0.25 
 
 Lead 0.50 *' 
 
 Silver 34.78 *' 
 
 Gold 0.03 
 
 Soluble in water : 12.76 •' 
 
 The lead carbonate assays 30 per cent. Lead, so far for 1 892. 
 Table III gives the comparison of [fineness of product in 
 silver for 1891-1892. 
 
THE RUSSELL PROCESS. 
 
 TABI.E III. 
 
 COMPARISON OF FINENESS OF PRODUCT IN SILVER, ETC. 
 
 1891-1892. 
 
 1 
 
 Year. 
 
 Ontario 
 Bullion. 
 
 Marsac 
 "Regular" 
 
 dried 
 Sulphides. 
 
 Marsac 
 
 Total 
 
 dried 
 
 Sulphides. 
 
 Marsac 
 Bullion. 
 
 Cost of market- 
 ing product 
 
 peroz.of silver 
 produced. 
 
 Price 
 obtained 
 per ounce 
 for silver. 
 
 Fine. 
 
 Fine. 
 
 Fine. 
 
 Fine. 
 
 Cts. 
 
 $ 
 
 Ontario 
 3.47 
 
 Marsac 
 
 Ontario 
 
 Marsac 
 0.9700 
 
 1891 
 1892 
 
 .425 
 .380 
 
 .337 
 .395 
 
 .313 
 .351 
 
 No 
 
 Sulphides 
 
 refined 
 
 at Mill. 
 
 .923 
 
 3.45 
 
 0.9755 
 
 The figures given for 1892 are up to Sept. ist. During 
 1 89 1 all the product of the Marsac Mill was shipped in the 
 dried state. The ' ' regular " sulphides referred to are the pre- 
 cipitates from the ' ' ordinary " and ' ' extra solutions. " 
 
 The ' ' total " sulphides include the ' ' wash water precipi- 
 tate " also. 
 
 During 1893 all the gold and silver in Marsac sulphides 
 will be parted and refined at the mill by a new wet process. 
 According to the terms of the contract which has been made, 
 the full corrected assay value of the sulphides produced at the 
 mill, is to be returned as silver bullion 998, and gold bullion 
 995 fine, which can be shipped directly to the mint, requiring 
 no further treatment. The total cost, according to the contract, 
 is to be I ){ cents per ounce of silver treated. 
 
 By the term ' ' full corrected assay value, " or ' ' exact 
 assay, " is meant the assay value of the sulphides, as determined 
 by the best method of fire assaying, plus the silver (and gold) 
 found by assaying the slag and cupel, which may be called the 
 by products of the assay, and which contain, on an average, 1.3 
 per cent, of the full value of the sulphides. 
 
THE RUSSELL PROCESS. 
 
 The following table gives the fineness of products in gold 
 for 1 89 1 and 1892. 
 
 TABLE ly. 
 
 FINENESS OF PRODUCTS IN GOLD. 
 
 1891-1892. 
 
 Year. 
 
 Ontario 
 Bullion. 
 
 Marsac 
 "Regular" 
 Sulphides. 
 
 Marsac 
 
 Total 
 
 Sulphides. 
 
 Marsac 
 Bullion. 
 
 Net price 
 
 obtained 
 
 per ounce 
 
 for gold. 
 
 Fine. 
 
 Fine. 
 
 Fine. 
 
 Fine. 
 
 $ 
 
 Ontario 
 
 0.00 
 20.67 
 
 Marsac 
 
 1891 
 1892 
 
 .00025 
 .00023 
 
 .00034 
 .00041 
 
 .00026 
 .00032 
 
 No Sulphides 
 refined 
 at Mill. 
 
 .00097 
 
 20.00 
 20.67 
 
 The table for 1892 goes up to Sept. first only. Both of 
 the above products of the Marsac are finer in gold than the 
 bullion of the Ontario. 
 
 Table Y covers only the year of 189 1, as no comparisons 
 are made on these points, except at the end of the year, and, 
 
 892. 
 
 therefore, can not now be given for 
 
 TABL.E V. 
 
 WATER, CHEMICALS, IRON AND POWER. 
 1891. 
 
 Water used 
 per ton. 
 
 Total 
 
 Chemicals and 
 
 quicksilver 
 
 per ton. 
 
 Wrought and 
 cast iron con- 
 sumed per 
 ton. 
 
 Power for driv- 
 ing' pans, stir- 
 ring&handling 
 solution, press- 
 ing and grind- 
 ing product. 
 
 Machinery 
 Expense. 
 
 Ontario. Marsac 
 
 Ontario. 1 Marsac. 
 
 Ontario. Marsac. 
 
 Ontario. Marsac. 
 
 Ontario. 1 Marsac, 
 
 Cubic feet. 
 
 $. 
 
 lbs. 
 
 H. P. 
 
 $ 
 
 400 
 
 56 
 
 1.315 
 
 0.900 
 
 5.5 0.05 
 
 108 
 
 8 
 
 0.31 
 
 1 
 0.07 
 
 The figures given on consumption of iron represent the 
 amount actually consumed, i. e., the amount purchased, less the 
 amount sold as ' ' scrap " to foundries and smelters. 
 
 The amount of w^ater given for Marsac includes that used 
 for sluicing out tailings, which is about 1 6 cubic feet per ton 
 of ore. 
 
8 THE, RUSSELL PROCESS. 
 
 The cost of chemicals per ton of ore for 1890 was ;$o.658, 
 and for 1891 ;^o.825, an increase per ton of $0.16'/, 
 
 This increase is due to use of warm sohitions and baser ore. 
 A comparison of results is of interest. 
 
 STATEMENT E. 
 
 1890 Value of ore 37.31 ozs. 
 
 1891 " " 39.10 ozs. 
 
 1890 Mill Extraction, cold solution, 50° F 88.77 per cent. 
 
 1891 " " warm solution, 100° F 91.57 per cent. 
 
 1890 Cost of chemicals, per ton of ore $0,658 
 
 1891 *' " " " $0,825 
 
 T4BL.E VI. 
 
 COMPAEISON OF CHEMICALS CONSUMED AT MARSAC MILL 
 
 WITH COLD (50°) AND WARM (100°) SOLUTION. 
 
 1890—1891. 
 
 Year. 
 
 Solution 
 how used. 
 
 Chemicals 
 
 consumed 
 
 per ton 
 
 of ore. 
 
 Cost of 
 
 chemicals 
 
 per ton 
 
 of ore. 
 
 Chemicals 
 per oz. of 
 
 silver 
 produced 
 
 Cost of 
 chemicals 
 per oz. of 
 
 silver 
 produced. 
 
 Silver 
 
 value of 
 
 ore treated. 
 
 Actual 
 
 extraction 
 
 based on 
 
 raw ore 
 
 value 
 
 0. Fah. 
 
 lbs. 
 
 $ 
 
 lbs. 
 
 $ 
 
 oz. 
 
 per cent. 
 
 1890 
 1891 
 
 Cold (50 F) 13.51 
 Wam(lOOF) 18.75 
 
 0.658 
 0.825 
 
 .424 0.0175 
 .521 0.0229 
 
 37.31 
 39.10 
 
 88.77 
 91.57 
 
 Note. — The cost of Marsac chemicals in Table V is for total mill 
 chemicals, of which only $0,825 belongs to the leaching department. 
 
 The above figures show a gain of 2.8-10 per cent, in ex- 
 traction for 1 89 1, with warm solutions, over 1890, when cold 
 solutions were used, amounting to 1.095 oz. per ton of ore. 
 
 STATEMENT F. 
 
 24,214 tons treated at 1.095 oz. additional extraction 26,514.33 ozs. 
 
 Less extra cost of chemicals per ton of ore $0,167 
 
 " " " " steam for heating solution 0.02 
 
 Total extra cost per ton !5l0.187 
 
 Making total extra cost for year % 4528.01 
 
 26,514.33 ozs. silver at average value 97c $ 25,718.90 
 
 Total extra cost for year. 4,528.01 
 
 Net gain for year $ 21,190.89 
 
THE RUSSELL PROCESS. 9 
 
 The total cost of all steam to leaching department is $o. 1 297 
 per ton of ore. This includes steam for — 
 
 Air compressor, which supplies air for stirring wash- 
 water and solutions. 
 
 Elevating solution to storage tanks, and pressure tank 
 for pressing all products. 
 
 Heating all solutions and wash water. 
 
 Dissolving caustic soda in making sodium sulphide. 
 
 Ejectors for leaching vats. 
 
 Ejectors for filtered solution. 
 
 Engine for precipitate grinder. 
 The cost of heating solutions is not over ^0.02 per ton of 
 ore. 
 
 Tables VII and VIII. — ^These give comparative figures, by 
 months, between amalgamation at the Ontario, and the Eussell 
 process attheMarsac, for 1891, using warm solutions. Coarser 
 crushing could probably be adopted at the Marsac w^ithout de- 
 creasing the extraction percentage. Little, however, w^ould be 
 gained by the change, as the capacity of the Mill would still be 
 limited by the capacity of the Ore Driers, which are already 
 being run to their limit. The Stetefeldt Furnace, with a 
 slightly increased draft, could probably treat 1 2 5 tons per day. 
 In former years, w^hile w orking decomposed ore from the upper 
 levels of the Daly Mine, which crushed very easily, as high as 
 95 tons per day have been roasted. 
 
 The comparison of fuel is between wood at the Ontario 
 and coal at the Marsac. While w^ood was used at the Marsac 
 the amount consumed was about .114 cords as against .153 cords 
 at the Ontario. 
 
 The temperatures represent that in the amalgamation pans 
 and that of the solution running out of the ore vats. Of course 
 the amount of water to be heated for amalgamation is much less 
 than that of the solutions for leaching. It is not always 
 necessary, how ever, to heat the leaching solutions, but as warm 
 solutions filter more rapidly than cold, where the leaching rate 
 is slow, or vat capacity insufiicient, the using of warm solution 
 permits of increased volume. The rates of leaching cold and 
 warm solutions, at Marsac, is as two and one-half to three. 
 
10 
 
 THE RUSSELL PROCESS. 
 
 
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12 THE RUSSELL PROCESS. 
 
 The chemicals and quicksilver represent the cost of what 
 is actually in use at any given time, but does not include the 
 supply in store. For the Ontario the amount, ;^956o, is the 
 actual value of the quicksilver in circulation; and for the Mar- 
 sac, ;^385 is the actual value of the hyposulphite, bluestone, 
 caustic soda, sulphur and soda ash in the leaching and precipi- 
 tating solutions. 
 
 The following table gives the per cent, of salt used, and 
 the extraction of silver at the Ontario and Marsac Mills, by 
 months, for 1892, up to December first, the fineness of crushing 
 being the same, and other statistics approximately the same, as 
 given in Tables 7 and 8. 
 
 The word "extraction," as employed in connection with 
 the Russell Process means " apparent extraction " from the ma- 
 terial charged to the leaching vats, unless it is stated to be 
 ' ' actual. " In calculating ' ' apparent extraction " only the values 
 per ton of ore and tailings, and the per cent, of soluble salts in 
 the ore, need be obtained; while for determining "actual ex- 
 traction" the total value of material treated, and the "clean up," 
 must be known. With the term ' ' actual extraction, " are used 
 also the expressions "from raw ore," or "from roasted ore," 
 and to be accurate it must also be stated whether the extractions 
 are based on the ' ' apparent values " or on the ' ' exact values, " 
 the latter value including the 5 to i 5 per cent, of silver and gold 
 which may enter the slag and cupel in assaying ores and tailings. 
 Unless otherwise stated "apparent values" are understood. 
 
THE RUSSELL PROCESS, 
 
 13 
 
 TABL.I: IX. 
 
 PER CENT. OF SALT USED AND MILL RESULTS. 
 
 1892. 
 
 Month. 
 
 January 
 
 February. . . 
 
 March 
 
 April 
 
 May 
 
 June 
 
 July 
 
 August 
 
 September. 
 
 October 
 
 November. 
 
 Average 
 
 Per Cent, of Salt Used. 
 
 Extraction of Silver. 
 
 Ontario. 
 
 Marsac. 
 
 Ontario. 
 
 Marsac. 
 
 Per Cent. 
 
 Per Cent. 
 
 Per cent. 
 
 Per Cent. 
 91.5 . 
 
 13.9 
 
 10.0 
 
 89.9 
 
 13.2 
 
 9.5 
 
 92.0 1 92.7 
 
 13.8 
 
 9.5 
 
 92.4 91.6 
 
 13.9 
 
 9.5 
 
 92.5 92.8 
 
 13.7 
 
 10.1 
 
 89.5 92.3 
 
 15.2 
 
 9.4 
 
 90.2 88.1 
 
 14.6 
 
 8.9 
 
 88.5 92.2 
 
 14.0 
 
 9.3 
 
 90.4 92.5 
 
 13.8 
 
 8.9 
 
 91.2 92.5 
 
 15.0 
 
 9.6 
 
 90.4 92.8 
 
 15.0 
 
 9.4 
 
 91.5 j 92.4 
 
 14.2 
 
 9.5 
 
 90.8 1 91.9 
 
 When red hot ore is ' ' wet down " the steam produced causes 
 a reduction of some of the silver compounds to a state in which 
 they are not readily soluble in the leaching solutions. 
 
 This injurious effect is greater on some ores than on others, 
 and on ore from the same mine is greater in proportion 'to its 
 baseness. 
 
 The mill extraction at the Marsac would be about 2 per 
 cent, higher, or 94 per cent, if the ore were charged dry and 
 cool to the ore vats, instead of ' ' wetting it down " on the cool- 
 ing floor Avhile red hot, as is now done. This would require 
 an enlargement of the present cooling floor, and an additional 
 expense of about thirteen cents per ton in handling the ore. 
 For instance, at the Aspen Mill, which has a large cooling floor 
 and where the roasted ore is always charged dry and cool to the 
 ore vats, the total cooling floor expenses, from the time the red 
 hot ore is dumped on the floor up to and including the charg- 
 ing of the ore to the leaching vats, are 49 cents. The cor- 
 responding expenses at the Marsac are 36 cents per ton. 
 
 The results given in the following table illustrate the in- 
 jurious effect of wetting down base ore, the ore treated being 
 composed of milling and shipping ore in the proportion pro- 
 duced at the mine. 
 
14 
 
 THE RUSSELL PROCESS. 
 
 TABLE X. 
 
 EFFECTS OF "WETTING DOWN," WHILE RED HOT, 
 BASE ONTARIO ORE. 
 
 Me&h of 
 Screen on 
 Battery. 
 
 Per cent, of 
 
 Salt used in 
 
 Roasting. 
 
 Silver, 
 
 Value of Raw 
 
 Ore per ton. 
 
 Per cent. 
 
 Extraction by 
 
 Leaching in Mill. 
 
 Mesh. 
 
 Per cent. 
 
 Ozs. 
 
 Per cent. 
 
 30 
 30 
 30 
 30 
 30 
 30 
 30 
 
 ! 
 
 tH 
 
 104.0 
 
 85.2 
 
 80.8 
 
 87.3 
 
 108.0 
 
 101.0 
 
 107.0 
 
 82.6 
 81.3 
 
 78.8 
 84.0 
 87.0 
 87.2 
 88.4 
 
 30 
 
 15-17 
 
 96.3 
 
 84.2 
 
 The mill extractions on charges of the same kind of ore not 
 wet down, l)ut charged dry and cool to the ore vats were from 
 92 to 93 per cent. 
 
 •At Aspen the ayerage assay office extractions from roasted 
 ore not wet down while hot on cooling floor are 8 1 .4 per cent, 
 by the old leaching process, and 92.5 per cent, by the Russell 
 Process. If the same ore is wet down on the cooling floor while 
 hot the above results become about 66.0 per cent, and 87.0 per 
 cent, respectively, or in other words, they are lowered i 5 and 
 5 per cent. 
 
 The results given in the following table are an illustration 
 of what can be done on Ontario ore (or on Marsac) by the Rus- 
 sell Process, if the ore is 7tol wet down while red hot, but 
 charged dry and cool to the ore vats, as is done at Aspen. 
 These mill runs, on which statistics are given in Table XI, were 
 made at the Ontario Mill, the ore being roasted in the Stetefeldt 
 Furnace and leached in the experimental plant at that mill. 
 The ore treated in the first three runs (26, 20 and 16 mesh 
 screens), was composed of a mixture of shipping and milling 
 ore, or an fiverage of all the ore produced by the Ontario Mine. 
 
THE RUSSELL PROCESS. 
 
 15 
 
 The analysis of this ore was approximately as follow\s : 
 
 STATEMENT G. 
 
 Silica ^ 55.21 Per Cent, 
 
 Alumina 13.14 " 
 
 Zinc 9.60 " 
 
 Lead 6.07 
 
 Sulphur 7.68 " 
 
 Iron ; 2.77 " 
 
 Copper 1.41 " 
 
 Antimony 1.20 " 
 
 Manganese 0.45 '* 
 
 Arsenic 0.20 " 
 
 TABL,i: XI. 
 
 MILL RUNS BY RUSSELL PROCESS ON ONTARIO ORE. 
 Charged Dry and Cool to Leaching Vats. 
 
 Mesh of 
 Screen 
 and size 
 of Wire 
 used on 
 Battery. 
 
 Tons 
 Crush d 
 in 24 
 hours 
 per 
 Stamp 
 
 Tons 
 Roast'd 
 per day 
 by one 
 furn'ce 
 
 Cords 
 of 
 
 Wood 
 used in 
 furn'ce 
 per ton 
 
 Horse 
 Power 
 req'rd 
 
 for 
 furn'ce 
 
 Labor per 
 ton includ- 
 ing the 
 Roasting 
 and Piling 
 on the 
 Cooling 
 Floor. 
 
 Per 
 cent. 
 
 of 
 Salt. 
 
 Per cent. 
 
 Mill 
 
 Extraction 
 
 by 
 Amalgama- 
 tion. 
 
 Per cent. 
 
 Mill 
 
 Extraction 
 
 by 
 
 Russell 
 
 Process. 
 
 26 Mesh 
 32 Wire 
 
 2 
 
 40 
 
 I 
 
 i 
 
 56 cts. 
 
 16 
 
 89.2 
 
 93.6 
 
 20 Mesh 
 28 Wire 
 
 21 
 
 55 
 
 1-10 
 
 i 
 
 48 " 
 
 12} 
 
 Too 
 coarse 
 
 for 
 
 Amalga- 
 mation. 
 
 97.0 
 
 16 Mesh 
 26 Wire 
 
 3i 
 
 70 
 
 1-12 
 
 3-5 
 
 41 " 
 
 12 
 
 97.1 
 
 10 Mesh 
 23 Wire 
 
 ^ 
 
 94 
 
 1-16 
 
 1 
 
 34 " 
 
 14 
 
 93,4 
 
 6 Mesh 
 20 Wire 
 
 Qh 
 
 126 
 
 1-20 
 
 M 
 
 26 " 
 
 8 
 
 91.9 
 
 Note, — Average results by Amalgamation at Ontario, with 26 mesh 
 screen, are 91.0 per cent. 
 
 The Ontario now mills, on an average (for 365 days per 
 year), 70.3 tons, of the analysis given at the beginning of this 
 article, and, for lack of milling capacity, ships to the smelters 
 3 I.I tons, averaging, so far, for 1892, 14.94 per cent. Lead 
 and 6.53 per cent. Zinc. But the average of the two, or the 
 total product of the mine, contains 5.93 per cent. Zinc and 5.83 
 per cent. Lead, or 3.67 per cent, less Zinc and j^ of i per cent, 
 less Lead than previously to 1 884, when all the ore was milled. 
 
1() 
 
 THE RUSSELL PROCESS. 
 
 The mill results at that time by the Russell Process were as 
 given in Table XI, with 26, 20 and 16 mesh screens, and 16; 
 1 2 J^ and 1 2 per cent, sa^, the roasted ore being charged dry 
 and cool to the ore vats. To mill the 100 tons, present total 
 product of the Ontario, instead of milling 70 and shipping 30, 
 would result in largely increased profits to the Company. 
 
 The value of gold in the ore is so small that the amount 
 treated and extracted is not figured up until the end of the year, 
 and so cannot yet be given for 1892. 
 
 The following table gives the results for 1 89 1 : 
 
 TABL,E XII. 
 
 ACTUAL EXTRACTION OF GOLD. 
 1891. 
 (1 oz. gold=$20.67.) 
 
 (Raw Ore.) 
 
 Mill. 
 
 Gold Value 
 
 per Ton of 
 
 Ore. 
 
 Total Gold 
 
 in Ore 
 for Year. 
 
 Actual Gold 
 
 in 
 
 Product. 
 
 Per Cent. 
 
 Extraction 
 
 of Gold. 
 
 Amount 
 Realized 
 on Gold. 
 
 
 $ 
 
 $ 
 
 $ 
 
 Per Cent. 
 
 $ 
 
 Ontario 
 Marsac 
 
 0.91 
 0.91 
 
 23,341.50 
 22,034.74 
 
 10,99L90 
 15,727.59 
 
 47.09 
 71.37 
 
 0.0 
 15,182.20 
 
 The amount and cost of chemicals per ton of ore at the 
 Marsac for 1891 is as follows, the prices given being the average 
 cost laid down at the mill : 
 
 STATEMENT H. 
 LIXIVIATION DEPARTMENT. 
 
 Bluestone 3.24 lbs. @ .0641 = ^0.2076 
 
 Hyposulphite of Soda 6.32 lbs. @ .0362= 0.2287 
 
 Caustic Soda 4.95 lbs. @ .0555= 0.2747 
 
 Sulphur 3.32 lbs. @ .0257= 0.0853 
 
 Soda Ash 0.92 lbs. @ .0317= 0.0292 
 
 18.75 lbs. @ .0440 $0.8255 
 
 BATTERY. 
 
 Sulphur, to rav,r ore 2.89 lbs. @ .0257 = $A 0743 
 
 Total Chemicals per Ton 21.64 lbs. @ .0416 = |0.8998 
 
THE RUSSELL PROCESS. IT 
 
 The sulphur to battery is amount added to raw ore to 
 assist in roasting. It will be noticed that the Daly ore 
 carries only one-third the amount of sulphur contained in On- 
 tario ore. 
 
 The following figures give the expenses at Marsac Mill, 
 (classified under five heads) from time the ore is piled on the cool- 
 ing floor after roasting, until the sulphide product is dried and 
 ready for shipment, or treatment in the Marsac Refinery. 
 
 These figures include the transferring of the ore from the 
 cooling floor to the ore vats. 
 
 STATEMENT I. 
 
 COST OF LIXIVIATING DEPARTMENT. 
 
 RUSSELL PROCESS. 
 
 MARSAC MILL. 
 
 Labor. 
 
 1 Foreman, @ |5.00 $ 5.00 
 
 3 Leachers, @ 4,00 12.00 
 
 8 Shovelers, @ 3.00 24.00 
 
 1 Pressman, @ 3.50 3.60 
 
 lRoustabout^@ 3.00 1.50 
 
 $46.00 
 365 days @ $46.00=$1 6,790. 00 -^- 24,214 tons= $ 0.6934 
 
 Chemicals. 
 
 Hyposulphite 152,808 lbs. @ .0362 == $5,531.64 
 
 Bluestone 78,569 lbs. @ .0641= 5,036.27 
 
 Caustic 119,741 lbs. @ .0555= 6,645.62 
 
 Sulphur 80,486 lbs. @ .0257= 2,068.49 
 
 Soda Ash 22,309 lbs. @ .0317= 707.19 
 
 453,913 lbs. @ .0440 $19,989.21 
 $19,989.21 ~ 24,214 tons = $ 0.8255 
 
 Repairs. 
 
 1 Machinist @ $4.00 
 
 Material and Supplies @ 2.50 
 
 $6.50 
 $6.50 X 365 days = $2,372.50 ~- 24,214 tons = $ 0.0979 
 
 Power, Steam, Etc, 
 
 Total cost for mill, labor, fuel, supplies and all repairs $12,559.55 
 
18 THE RUSSELL PROCESS. 
 
 Proportions by Actual Test. 
 
 Drying, Crushing and Roasting \ 
 
 Leaching Department \ 
 
 $12,559.65 -^ 4 = $3,139.89-^ 24,214 tons = % 0.1297 
 
 Assay Office. 
 
 Labor, fuel and supplies, actual $3,013.23 
 
 Leaching Department, proportion l 2,008.82 
 
 $2,008.82 -^- 24,214 tons = , $ 0.0830 
 
 Total cost per ton of Ore, ... $ 1.8295 
 
 SUMMARY. 
 
 The following table gives a summary of the comparisons 
 
 between the Ontario and Marsac Mill expenses and extractions, 
 
 for 1 89 1. 
 
 NOTE — The "Product Expense" given below, while apparently 
 in favor of Ontario, is, in reality, slightly in favor of Marsac, as the 
 product of the latter mill happened to be sold at times when silver 
 averaged lower in price than when Ontario product was disposed of. 
 
 STATEMENT J. 
 COMPARISON OF ONTARIO AND MARSAC 
 
 I'rom Compayties' Annual Report. 
 
 MILL EXPENSES. 
 
 Cost per 
 
 Ontario— Amalgamation. ton Ol Ore. 
 
 Milling $8.93 
 
 Product Expense 1.23 
 
 $10.16 
 Marsac — Russell Process. 
 
 Milling $6.27 
 
 Product Expense 1.23] 
 
 $7.50i 
 
 Total difference in Mill expenses $2. 65 J 
 
 ACTUAL EXTRACTION OF SILVER. (rAW ORE ) 
 
 Ontario. Actual Mill Extraction 91.0 
 
 Marsac. Actual Mill Extraction 91.57 
 
 Difference in Mill Extraction 0.57% 
 
 Difference in Mill Extraction for 39.10 ozs. ore, $0.21i 
 
THE RUSSELL PROCESS. ■ '19 
 
 ACTUAL EXTRACTION OF GOLD. (rAW ORE.) 
 (See Table XII.) 
 
 Ontario. Mill Extraction, Gold Realized |0.0 
 
 Mars AC. Mill Extraction, Gold Realized per ton 0.63^ 
 
 Difference per ton in favor of Marsac fO.63^ 
 
 Total net difference per ton in favor of Marsac $3. 50 J 
 
 « 
 
 RECAPITULATION. (Ontario Tonnage.) 
 
 25^650 tons of ore milled in 1891, at difference 
 of $3.50| per ton (or saving by Marsac 
 over Ontario, per year) $91,057.09 
 
 In the case of most ores, a comparison as to extraction, 
 etc., between amalgamation and the Russell Process would 
 probably be much more in favor of the latter, as there are but 
 few mills in which as good work is done as at the Ontario. 
 Against the twenty-two points of comparison given below, amal- 
 gamation exceeds the Russell Process in one point only, viz : 
 Fineness of product in silver (Table III). Although for this 
 year (1892) even this one point will be in favor of Lixiviation, 
 the product now being refined at the mill, while in 1893 the 
 product will be both refined and ' ' parted. " 
 
 The Russell Process has the advantage over amalgamation 
 in the following twenty-two points, the difference (omitting cost 
 of plant) amounting to over ;^3.oo per ton of ore. 
 
 I . — -Coarseness of crushing. (Tables i , 7 and 11.) 
 
 2. — Percentage of salt used. 
 
 3. — Fuel consumed. , 
 
 4. — Capacity of roasting furnace. 
 
 5. — Weight of charges. 
 
 6. — ^Water used. 
 
 7. — Labor. 
 
 8. — Power. 
 
 9. — Machinery expense. ' 
 I o. — Temperatures. 
 1 1 . — Iron. 
 12. — Chemicals per ton. . 
 
 ( " 
 
 7, 9 and II.) 
 
 ( " 
 
 7 and II.) 
 
 ( " 
 
 7 and II.) 
 
 (Table 
 
 8.) 
 
 ( " 
 
 50 
 
 (Statement A.) 
 
 (Table 
 
 5-) 
 
 ( " 
 
 50 
 
 ( " 
 
 8.) 
 
 ( " 
 
 50 
 
 i 41 
 
 50 
 
20 
 
 THE RUSSELL PROCESS. 
 
 (Table 8.) 
 Extraction of silver. (Tables 8, g and 
 
 — Extraction of gold. (Table I2.) 
 
 — Less copper— baseness of product. ( ' ' 2. ) 
 
 13. — Chemicals in use. 
 
 14 
 15 
 16 
 
 17 
 
 I 
 
 20 
 21 
 
 22 
 
 -Cost of marketing silver. ( " 3.) 
 
 . — Cost of marketing gold. (Tables 4 and 12.) 
 
 -Fineness of product in gold. (Table 4.) 
 -Total cost of treatment. (Statement J. ) 
 
 . — Net profits per ton. (Statement J. ) 
 
 -Less cost of plant. (Statement A.) 
 
 Or the comparison may be stated as follows, using Marsac 
 figures as a basis: 
 
 To treat about the same number of tons of ore per day, of 
 approximately the same composition as at the Marsac, the On- 
 tario (amalgamation) requires 45 per cent, more power, 39 per 
 cent, more labor, 30 per cent, more stamps, twice the number 
 of furnaces, 48 per cent, more salt, and 40 per cent, greater cost 
 of chemicals, and yet yields a less per cent, both of gold and 
 silver than the Marsac (Russell Process). 
 
 Note. — The Ontario Company are now erecting a Russell Process 
 Leaching Plant, of 200 tons daily capacity, for the treatment of old 
 tailings which have been produced from their mill by amalgamation in 
 former years. 
 
 These tailings will be transferred directly from the "pits" to the 
 leaching vats and leached without any drying, crushing, roasting or 
 other preliminary treatment. The actual extraction from these tailings 
 by the Russell Process averages 36 per cent, of the Silver and 64 per 
 cent, of the Gold, at a total expense of fl.lG, including hauling, loading 
 and treatment. 
 
 The Ontario Company are also proposing to erect a Rus- 
 sell Process Leaching department to replace their present amalgamat- 
 ing plant, which will be discarded. 
 
 All crushing and roasting will be done in the present mill, the 
 roasted ore being thence transferred to the leaching vats, instead of to 
 the amalgamating pans as formerly. 
 
 The entire product of the Ontario Mine, averaging 70 tons milling 
 and 31 tons smelting ore, per day, will then be treated by the Russell 
 Process, in the new plant which will have a capacity of 100 to 110 tons 
 of ore per day. 
 
 The total cost of the whole 300-ton plant is estimated at $75,000, 
 exclusive of grading.