This section is from "Scientific American Supplement". Also available from Amazon: Scientific American Reference Book.
Mining laborers generally can neither read nor write, and when employed in mines distant from habitations or towns, live and sleep therein, or in the open air, depending on the season or the weather. In a few mines the laborers are, however, provided with suitable dwelling places, and a relief fund is in existence for the succor of the families of those who die in the service. This fund is greatly opposed by the miners, from whose wages from 1 to 2 per cent. is deducted for its maintenance. In the absence of a fund of this character, the sick or infirm are abandoned by their companions and left to die. Generally miners are inoffensive when fairly dealt with. They are said to be indolent and dishonest as a rule. The managers of mines receive from 3,000 to 5,000 lire per annum; chief miners from 1,500 to 2,500 lire; surveyors, 700 to 1,000 lire; and weighers and clerks, from 1,000 to 2,000 lire per annum. The total number of mining laborers in Sicily is estimated at about 25,000.
The ore for fusion of the first grade as to yield contains from 20 to 25 per cent. of sulphur, that of the second grade from 15 to 20 per cent., and of the third grade 10 to 15 per cent. The usual means adopted for extracting sulphur from the ore is heat, which attains the height of 400 degrees Centigrade, smelting with the kiln, which in Sicilian dialect is called a "calcarone." The "calcarone" is capable of smelting several thousand tons of ore at a time and is operated in the open air. Part of the sulphur is burned in the process of smelting in order to liquefy the remainder. "Calcaroni" are situated as closely to the mouth of a shaft as possible, and if practicable on the side of a hill, in order that when the process of smelting is complete, the sulphur may run down the hill in channels prepared for the purpose. The shop of a "calcarone" is circular and the floor has an inclination of from 10 to 15 degrees. A design of a "calcarone" is herewith inclosed. The circular wall is made of rude stone work, cemented together with gypsum. The thickness of the wall at the back is 0.50 meter, and from this it gradually becomes thicker until in front, where it is 1 meter, when the diameter is to be 10 meters.
In front of the thickest part of the wall an opening is left, measuring 1.20 meters high and 0.25 meter broad.
Through this opening the liquid sulphur flows. Upon each side of this opening two walls are built at right angles with the circular wall, in order to strengthen the front of the kiln. These walls are 80 centimeters thick each and are roofed. A door is hinged to these walls, thus forming a small room in front of each kiln in which the keeper thereof resides from the commencement to the termination of the flow of sulphur. The inclined floor of the kiln is made of stone work and is covered with "ginesi," the name given to the refuse of a former process of smelting. The stone work is 20 centimeters thick, and the "ginesi" covering 25 centimeters, which gradually becomes thicker as it approaches its lowest extremity. The front part of the circular wall is 3.50 meters high and the back 1.80 meters. The interior of the wall is plastered with gypsum in order to render it impermeable.
The cost of a "calcarone" of about 500 tons capacity is 800 lire. The capacity varies from 40 to 5,000 tons, or more, depending upon circumstances. If a mine is enabled to smelt the whole year round, the smaller "calcaroni," being more easily managed, are preferred; the inverse is the case as to the larger "calcaroni," when this is impracticable. When a "calcarone" is situated within 100 meters of a cereal farm, its operation is prohibited by law during the summer, lest the fumes of the sulphur should destroy the crop.
When, however, the distance is greater from the farm or farms than 100 meters, smelting is permitted; but should any damage ensue to the crops as a result of the fumes, the owners of the "calcaroni" are required to liquidate it. Therefore the mines which are favorably situated smelt the entire year, and employ "calcaroni" of from 40 to 500 tons, as there is less risk of a process failing, which occasionally happens, and for the reason that the ore can be smelted as soon as it is extracted; whereas, when kilns or "calcaroni" are situated within or adjacent to the limit adverted to, they can only be operated five or six months in the year, consequent upon which the ore is necessarily stacked up all through the summer or until such time as smelting may be commenced without endangering the crops, when it becomes necessary to use "calcaroni" whose capacity amounts to several thousand tons. As intimated, these large "calcaroni" are not so manageable as those of smaller dimensions, and as a result many thousands of tons of sulphur are lost in the process of smelting, besides perhaps the loss of an entire year in labor.
Again, the ore deteriorates or depreciates when long exposed to the air and rain, all of which, when practicable, render the kilns or "calcaroni" of the smaller capacity more advantageous and lucrative to those operating sulphur mines in Sicily. Smelting with a "calcarone" of 200 tons capacity consumes thirty days, one of 800 tons 60 days, and with a "calcarone" of 2,000 tons capacity from 90 to 120 days are consumed.
In loading or filling the "calcaroni," the larger blocks of ore are placed at the bottom as well as against the mouth, in order to keep the lower part of the kiln as cool as possible with a view of preventing the liquid sulphur from becoming ignited as it passes down to where it makes its exit, etc. The blocks of ore thus first placed in position are, for obvious reasons, the most sterile. After the foundation is thoroughly laid the building of the "pile" is proceeded with, the larger blocks being placed in the center to form, as it were, the backbone of the pile; the smaller blocks of ore are arranged on the outside of these and in the interstices. The shape or form of the pile when completed is similar to a truncated cone, and when burning the kiln looks like a small volcano. When the kiln has been filled with ore, the whole is covered with ginesi with a view of preventing the escape of the fumes. The ore is then ignited by means of bundles of straw, impregnated or saturated with sulphur, being held above the thin portion of the top of the kiln, which is at once closed with ginesi, and the "calcarone" is left to itself for about a week. During the burning process the flames gradually descend, and the sulphur contained in the ore is melted by the heat from above.
 
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