The bench sweeps must be burned out before being
melted. In this way things like brushes,
sanding disks, shellac, etc. that would hinder a melt and displace the precious
metals into the slag that floats to the top of the melt are reduced to a carbon
ash which then will flux off into the slag allowing the metals to melt into the
bar. Here the bench sweeps are put on a
layer of paper in the burnout pan. The
paper causes a carbon layer to form between the sweeps and the pan keeping
anything from sticking to the pan.
Here the bench sweeps are being burnt.
Here are the bench sweeps after they have been burnt.
They are demagnetized to remove mostly iron based material
that would not melt properly and thus not allow for an accurate assay.
Bench sweeps typically contain a large percentage of non-metal, mostly carbon based material. In
the melting process the metal needs to efficiently separate from the this
extraneous material. To facilitate this
a flux (borax) is added.
To further assure a good melt an oxidizing agent (soda ash)
is added to help oxidize any remaining organics and assure that they will not
interfere and be fluxed off into the borax.
It is all thoroughly mixed.
It is smelted down with more being added as it melts.
Once everything has been added and melted, it is stirred to
assure the melt is complete and homogeneous.
Once completely melted and sampled, it is poured into a
form.
The bar after pouring, cooling in the form.
The bar on the melt table after removal from the form. A thick layer of slag is visible on the
bottom (the bar having been flipped over in the process of removal from the form) that comes
from a mixture of the flux and extraneous material.
The bar with slag being put into a bath of water to cool.
The final bar with pin samples being weighed after cleaning. One of the samples will be send off to assay to determine the per cent gold present. Since the bar is homogeneous, the weight of the bar is multiplied by the assay percent and the amount of pure gold present in the bar is determined to within better than 1/10 of 1 percent. The bar itself is then added to many similar type bars and goes into the refining stream to have the fine gold actually separated from the other metals and reclaimed for further use. To see how this is done view our slideshow:
Final Gold Refining Process - Accent Diamond Removal.