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Narrator: THE OLDEST EXISTING
CHINESE FANS,
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00:00:55,241 --> 00:00:58,931
MADE OF WOVEN BAMBOO,
DATE TO THE 2nd CENTURY B.C.
3
00:00:58,931 --> 00:01:01,448
THE FOLDING FAN
WAS INVENTED IN JAPAN
4
00:01:01,448 --> 00:01:03,413
BETWEEN THE 6th AND 9th CENTURY.
5
00:01:03,413 --> 00:01:06,034
FANS WERE TYPICALLY MADE
OF PAPER OR SILK,
6
00:01:06,034 --> 00:01:09,517
AND FAMOUS ARTISTS WERE OFTEN
COMMISSIONED TO PAINT THEM.
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00:01:14,068 --> 00:01:16,275
THE TRADITIONAL ASIAN FAN --
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00:01:16,275 --> 00:01:19,344
AN OBJECT OF BEAUTY
WITH A PRACTICAL PURPOSE.
9
00:01:19,344 --> 00:01:23,034
THE STRUCTURE IS COMPRISED
OF BAMBOO STICKS, CALLED RIBS.
10
00:01:23,034 --> 00:01:26,137
THE PAPER SURFACE
IS CALLED THE LEAF.
11
00:01:26,137 --> 00:01:28,965
IN THIS FAN WORKSHOP
IN NORTHERN THAILAND,
12
00:01:28,965 --> 00:01:32,448
THEY BEGIN WITH NARROW POLES
OF LOCALLY HARVESTED BAMBOO.
13
00:01:32,448 --> 00:01:33,862
WITH A SHARP KNIFE,
14
00:01:33,862 --> 00:01:36,586
WORKERS CUT THEM TO THE
APPROXIMATE LENGTH OF THE RIBS,
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00:01:36,586 --> 00:01:39,344
THEN SPLIT THEM DOWN THE MIDDLE.
16
00:01:39,344 --> 00:01:41,000
USING TRADITIONAL BLADES,
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00:01:41,000 --> 00:01:44,206
THEY SHAVE EACH BAMBOO STRIP
TO THE SHAPE OF A RIB.
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RIBS ARE TYPICALLY
ABOUT 7/100 OF AN INCH THICK
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00:01:47,379 --> 00:01:48,758
AND PERFECTLY FLAT
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00:01:48,758 --> 00:01:54,344
SO THAT THEY CAN SMOOTHLY SLIDE
ON TOP OF ONE ANOTHER.
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00:01:54,344 --> 00:01:58,413
WORKERS DRILL A HOLE IN EACH RIB
2 TO 3 INCHES ABOVE THE BASE,
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00:01:58,413 --> 00:02:00,172
DEPENDING ON THE FAN SIZE.
23
00:02:00,172 --> 00:02:02,827
THEN THEY ASSEMBLE THE RIBS
ON A BOLT.
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00:02:02,827 --> 00:02:05,241
THE NUMBER OF RIBS
AND THEIR LENGTH
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00:02:05,241 --> 00:02:07,275
ARE WHAT DETERMINE A FAN'S SIZE.
26
00:02:07,275 --> 00:02:10,517
THE TWO RIBS ON THE EXTREMITIES
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ARE WIDER AND THICKER
THAN THE OTHERS
28
00:02:12,241 --> 00:02:13,586
AND ARE ROUNDED ON THE OUTSIDE.
29
00:02:13,586 --> 00:02:15,655
THESE ARE CALLED THUMB GUARDS
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00:02:15,655 --> 00:02:19,137
BECAUSE YOU FLICK YOUR THUMB
ON THEM TO OPEN THE FAN
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00:02:19,137 --> 00:02:22,724
AND THEY GUARD THE RIBS
IN BETWEEN FROM DAMAGE.
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00:02:22,724 --> 00:02:23,965
TO MAKE THE LEAF,
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00:02:23,965 --> 00:02:26,241
THEY BEGIN
BY SPREADING THE RIBS,
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00:02:26,241 --> 00:02:27,827
SPACING THEM OUT EVENLY.
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00:02:27,827 --> 00:02:29,758
THEY LAY THIS ONTO WHITE COTTON
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00:02:29,758 --> 00:02:32,758
AND CUT OUT THE SEMICIRCULAR
SHAPE OF THE LEAF
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WITH THE FABRIC EXTENDING
1 1/2 TO 2 1/2 INCHES
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00:02:36,068 --> 00:02:37,586
BEYOND THE RIB TIPS.
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00:02:37,586 --> 00:02:40,172
THIS FABRIC WILL BE
THE LEAF'S STRUCTURAL BACKING,
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00:02:40,172 --> 00:02:44,137
GIVING THE PAPER RIGIDITY
AND STRENGTH.
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00:02:44,137 --> 00:02:48,413
THEY MAKE THAT PAPER
JUST AS THEIR ANCESTORS DID --
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00:02:48,413 --> 00:02:51,103
MIXING THE FIBROUS BARK
OF THE MULBERRY TREE
43
00:02:51,103 --> 00:02:52,379
WITH NATURAL DYES --
44
00:02:52,379 --> 00:02:54,413
THE MARIGOLD FLOWER FOR YELLOW,
FOR EXAMPLE,
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00:02:54,413 --> 00:02:56,517
OR, AS WE SEE HERE,
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00:02:56,517 --> 00:03:01,758
THE ROOT OF THE MADDER PLANT
FOR VIBRANT RED.
47
00:03:01,758 --> 00:03:04,689
THEY MIX THE DYESTUFF
WITH THE MULBERRY BARK FIBERS,
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00:03:04,689 --> 00:03:06,965
THEN GATHER A THIN LAYER
OF DYED FIBERS
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00:03:06,965 --> 00:03:09,137
ONTO A RECTANGULAR
MESH SCREEN.
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00:03:09,137 --> 00:03:11,413
THEY KEEP REPEATING
THIS PROCESS,
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00:03:11,413 --> 00:03:12,827
ADDING LAYERS
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00:03:12,827 --> 00:03:15,241
UNTIL THEY BUILD UP
THE PAPER THICKNESS THEY NEED.
53
00:03:15,241 --> 00:03:17,517
THEN THEY LET THE FIBERS DRY
IN THE SUN
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00:03:17,517 --> 00:03:20,413
INTO A FINISHED SHEET OF PAPER.
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00:03:20,413 --> 00:03:21,793
WHEN THE PAPER'S READY,
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00:03:21,793 --> 00:03:24,862
THEY CUT A PIECE TO MATCH
THE SHAPE OF THE COTTON BACKING
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00:03:24,862 --> 00:03:26,206
AND IRON THEM TOGETHER.
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00:03:26,206 --> 00:03:28,965
THE TWO LAYERS
NATURALLY ADHERE TO EACH OTHER,
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00:03:28,965 --> 00:03:32,344
THANKS TO THE PAPER'S MOISTURE
AND A COMPOUND IN ITS FIBERS,
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00:03:32,344 --> 00:03:35,413
CALLED LIGNIN,
WHICH ACTS AS A NATURAL GLUE.
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THEY FOLD THE LEAF IN HALF
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00:03:37,206 --> 00:03:38,551
AND TRACE A TEMPLATE
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00:03:38,551 --> 00:03:41,448
IN THE SHAPE OF
THE LOWER SECTION OF THE FAN,
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00:03:41,448 --> 00:03:43,137
WHERE NO PAPER IS REQUIRED.
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00:03:43,137 --> 00:03:44,931
THEN THEY CUT THIS PART OFF.
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00:03:48,206 --> 00:03:51,000
THEY BRUSH HOMEMADE GLUE
MADE WITH WHITE FLOUR
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ONTO THE PARTS OF THE RIBS
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THAT WILL BE IN CONTACT
WITH THE LEAF.
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00:03:55,379 --> 00:03:56,620
THEY LAY THE RIBS ON THE PAPER
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00:03:56,620 --> 00:03:59,344
AND, WITH AN UPWARD
SWEEPING MOTION,
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00:03:59,344 --> 00:04:00,620
PRESS THEM DOWN,
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00:04:00,620 --> 00:04:02,655
AT THE SAME TIME
WIPING AWAY THE EXCESS GLUE.
73
00:04:02,655 --> 00:04:05,931
NEXT, THEY TRIM THE LEAF,
74
00:04:05,931 --> 00:04:09,068
LEAVING ABOUT 7/10 OF AN INCH
BEYOND THE TIPS OF THE RIBS.
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00:04:13,241 --> 00:04:15,034
THEY GLUE THE EDGE...
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00:04:17,034 --> 00:04:19,827
...AND FOLD IT BACK
OVER THE RIBS.
77
00:04:28,724 --> 00:04:32,551
THEN THEY TRIM THE EDGES
ALONG THE THUMB GUARDS.
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00:04:32,551 --> 00:04:37,448
NOW FOR THE MOST DELICATE STEP
OF THE ENTIRE PROCESS --
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00:04:37,448 --> 00:04:39,413
FOLDING THE FAN
FOR THE FIRST TIME.
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00:04:39,413 --> 00:04:42,689
EACH FOLD IS PERMANENT
AND WILL GIVE THE FAN ITS FORM,
81
00:04:42,689 --> 00:04:47,413
BOTH OPEN AND CLOSED,
SO PRECISION IS EVERYTHING.
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NOW THE FULLY CONSTRUCTED FAN
IS READY FOR DECORATION
83
00:04:50,620 --> 00:04:52,137
WITH WATER-BASED ACRYLIC PAINTS.
84
00:04:52,137 --> 00:04:57,103
SOMETIMES THE CUSTOMER REQUESTS
A CERTAIN THEME OR SCENE,
85
00:04:57,103 --> 00:05:01,931
BUT USUALLY IT'S LEFT
TO THE ARTIST'S CREATIVITY.
86
00:05:04,965 --> 00:05:07,137
THE ARTIST
CAN MANIPULATE THE PAINTS
87
00:05:07,137 --> 00:05:08,862
TO PRODUCE A RANGE OF EFFECTS,
88
00:05:08,862 --> 00:05:11,206
MODIFYING WITH ACRYLIC GELS,
MEDIA, OR PASTES
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00:05:11,206 --> 00:05:13,241
TO CREATE THE BOLD EFFECT
OF OIL PAINT
90
00:05:13,241 --> 00:05:16,413
AND DILUTING WITH WATER
TO VARYING DEGREES
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00:05:16,413 --> 00:05:21,310
TO CREATE A TRANSPARENT EFFECT
MUCH LIKE WATERCOLORS.
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00:05:21,310 --> 00:05:24,448
THE FINAL TOUCH
IS WHAT'S KNOWN AS PIPING --
93
00:05:24,448 --> 00:05:27,310
PAINT APPLIED
THROUGH A CONE-SHAPED TIP
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00:05:27,310 --> 00:05:30,103
TO PRODUCE A RAISED LINE.
95
00:05:30,103 --> 00:05:33,034
THIS HIGHLIGHTS THE ARTWORK
WITH RAISED DETAILS.
96
00:05:36,827 --> 00:05:39,655
THE PAINT BECOMES
WATER-RESISTANT ONCE DRY,
97
00:05:39,655 --> 00:05:42,000
PROTECTING THE ARTWORK
FROM DAMAGE
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00:05:42,000 --> 00:05:44,344
AND ENSURING
THIS ANCIENT OBJET D'ART
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WILL ALWAYS BE SIMPLY FANTASTIC.
100
00:06:01,068 --> 00:06:02,379
Narrator: WALNUT OIL
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HAS A DISTINCTIVE, MILD,
NUTTY FLAVOR AND AROMA.
102
00:06:05,275 --> 00:06:06,586
IT'S ALSO NUTRITIOUS
103
00:06:06,586 --> 00:06:09,172
BECAUSE IT'S HIGH
IN OMEGA-3 FATTY ACIDS,
104
00:06:09,172 --> 00:06:11,586
WHICH ARE CRUCIAL
FOR BRAIN FUNCTION,
105
00:06:11,586 --> 00:06:12,896
REDUCE INFLAMMATION,
106
00:06:12,896 --> 00:06:15,689
AND MAY EVEN HELP LOWER THE RISK
OF HEART DISEASE,
107
00:06:15,689 --> 00:06:17,965
ARTHRITIS,
AND OTHER CHRONIC CONDITIONS.
108
00:06:22,551 --> 00:06:25,413
WALNUT OIL IS SOMETIMES USED
FOR SAUTéING,
109
00:06:25,413 --> 00:06:27,793
BUT IT'S MORE OFTEN
CONSUMED COLD,
110
00:06:27,793 --> 00:06:30,137
TYPICALLY IN SALAD DRESSINGS.
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00:06:30,137 --> 00:06:32,344
WALNUT OIL
FOR NONCULINARY PURPOSES
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00:06:32,344 --> 00:06:36,517
GOES THROUGH A REFINING PROCESS
WHICH REMOVES THE FLAVOR.
113
00:06:36,517 --> 00:06:39,758
WALNUT OIL PRODUCED
FOR GASTRONOMY IS UNREFINED,
114
00:06:39,758 --> 00:06:42,551
SO IT RETAINS ITS NUTTY TASTE
AND SCENT.
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00:06:45,931 --> 00:06:49,517
WALNUT OIL HAS ONE INGREDIENT
AND ONE INGREDIENT ONLY --
116
00:06:49,517 --> 00:06:51,620
ENGLISH WALNUTS.
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00:06:51,620 --> 00:06:55,551
THE OIL FACTORY BUYS THEM FROM
THE SUPPLIER ALREADY SHELLED.
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00:06:59,517 --> 00:07:02,275
PRODUCTION METHODS
ARE MUCH THE SAME AS THEY WERE
119
00:07:02,275 --> 00:07:04,103
150 YEARS AGO.
120
00:07:04,103 --> 00:07:07,793
THE FIRST STEP IS TO SHOVEL
THE WALNUTS INTO A GRINDER.
121
00:07:07,793 --> 00:07:09,000
THE GRINDER PULVERIZES
122
00:07:09,000 --> 00:07:12,000
THIS COMBINATION OF FULL KERNELS
AND BROKEN PIECES
123
00:07:12,000 --> 00:07:14,758
UNTIL EVERYTHING'S
FAIRLY UNIFORM,
124
00:07:14,758 --> 00:07:18,068
ROUGHLY 1/10 OF AN INCH IN SIZE.
125
00:07:18,068 --> 00:07:20,482
NEXT STEP -- ROASTING.
126
00:07:20,482 --> 00:07:22,517
WORKERS POUR THE GROUND WALNUTS
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00:07:22,517 --> 00:07:25,241
INTO A CAST-IRON KETTLE
ON A GAS BURNER.
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00:07:25,241 --> 00:07:26,827
FOR 30 MINUTES OR SO,
129
00:07:26,827 --> 00:07:29,689
A ROTATING ARM
CONTINUOUSLY STIRS THEM
130
00:07:29,689 --> 00:07:32,068
TO ENSURE THEY ROAST EVENLY.
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00:07:32,068 --> 00:07:36,241
ROASTING ENHANCES
BOTH THE FLAVOR AND AROMA.
132
00:07:38,241 --> 00:07:41,034
THE SHELLED WALNUTS HAVE GONE
FROM LARGE PIECES
133
00:07:41,034 --> 00:07:45,034
TO GROUND PIECES
TO ROASTED PIECES.
134
00:07:45,034 --> 00:07:49,482
NOW THEY'RE READY TO HAVE
THE OIL SQUEEZED OUT OF THEM.
135
00:07:49,482 --> 00:07:55,413
THIS CAST-IRON EXPELLER PRESS
DATES BACK TO THE EARLY 1900s.
136
00:07:55,413 --> 00:07:59,413
WORKERS LINE THE BOTTOM WITH
A MAT MADE OF NATURAL FIBERS.
137
00:07:59,413 --> 00:08:04,034
THIS WILL PREVENT THE WALNUTS
FROM LEAKING OUT UNDER PRESSURE.
138
00:08:04,034 --> 00:08:07,793
AFTER LOADING THE PRESS
WITH THE WALNUTS,
139
00:08:07,793 --> 00:08:11,000
THEY CLOSE IT UP
140
00:08:11,000 --> 00:08:13,206
AND SET THE PRESS IN POSITION.
141
00:08:16,068 --> 00:08:19,000
THEN THEY RELEASE THE PISTON.
142
00:08:19,000 --> 00:08:22,241
IT DESCENDS AND APPLIES
2,800 POUNDS PER SQUARE INCH,
143
00:08:22,241 --> 00:08:24,137
CRUSHING THE WALNUTS
144
00:08:24,137 --> 00:08:27,689
AND EXPELLING THE OIL
IN THE PROCESS.
145
00:08:27,689 --> 00:08:30,655
THE OIL EXITS THE PRESS
146
00:08:30,655 --> 00:08:33,551
THROUGH SMALL SLOTS
AROUND THE PERIMETER,
147
00:08:33,551 --> 00:08:35,172
FLOWS DOWN TO A TROUGH,
148
00:08:35,172 --> 00:08:38,172
WHICH CHANNELS IT TO A SPOUT,
149
00:08:38,172 --> 00:08:43,206
WHICH POURS IT
INTO A COLLECTION VAT.
150
00:08:43,206 --> 00:08:46,551
4 1/2 POUNDS OF NUTS
YIELDS 1 QUART OF OIL.
151
00:08:56,793 --> 00:09:00,241
WHAT'S LEFT IN THE PRESS
IS WALNUT MEAL.
152
00:09:00,241 --> 00:09:04,517
IT'S USED BY PASTRY CHEFS
TO ADD A NUTTY CRUNCH TO CAKES.
153
00:09:04,517 --> 00:09:07,724
IT'S ALSO SOLD TO FARMERS
WHO USE IT FOR CATTLE FEED.
154
00:09:10,793 --> 00:09:12,965
THE EXTRACTED OIL, MEANWHILE,
155
00:09:12,965 --> 00:09:15,758
MOVES ON TO THE LAST PHASE
OF THE PROCESS --
156
00:09:15,758 --> 00:09:17,931
FILTRATION.
157
00:09:17,931 --> 00:09:21,758
THE FILTER PRESS IS COMPRISED
OF 16 GROOVED PLATES
158
00:09:21,758 --> 00:09:25,965
MADE OF FOOD-SAFE PLASTIC,
WITH PAPER FILTERS IN BETWEEN.
159
00:09:31,275 --> 00:09:33,965
WORKERS COMPRESS THE PLATES
AND FILTERS...
160
00:09:39,172 --> 00:09:41,034
...THEN START UP
A POWERFUL PUMP,
161
00:09:41,034 --> 00:09:42,448
WHICH FORCES THE WALNUT OIL
162
00:09:42,448 --> 00:09:45,862
FROM ONE END OF THE PRESS
TO THE OTHER.
163
00:09:45,862 --> 00:09:49,275
ALONG THE WAY, THE FILTERS TRAP
ALL THE MINISCULE PARTICLES
164
00:09:49,275 --> 00:09:52,241
OF WALNUT, WAX,
AND OTHER NATURAL MATERIALS,
165
00:09:52,241 --> 00:09:54,862
CLARIFYING THE OIL.
166
00:09:54,862 --> 00:09:57,862
THIS PROCESS TAKES A FEW HOURS,
167
00:09:57,862 --> 00:10:01,551
AT THE END OF WHICH
THE ONCE-CLOUDY OIL IS CLEAR.
168
00:10:03,758 --> 00:10:06,931
PACKAGING WALNUT OIL
IN CLEAR GLASS BOTTLES
169
00:10:06,931 --> 00:10:08,931
WOULD LOOK APPETIZING
170
00:10:08,931 --> 00:10:12,034
BUT WOULD ACTUALLY SHORTEN
THE PRODUCT'S SHELF LIFE.
171
00:10:12,034 --> 00:10:15,862
THAT'S BECAUSE WALNUT OIL
IS RICH IN OMEGA-3 FATTY ACIDS,
172
00:10:15,862 --> 00:10:18,827
WHICH, WHILE GOOD FOR YOU,
ARE SENSITIVE TO LIGHT.
173
00:10:18,827 --> 00:10:23,000
THEREFORE, WALNUT OIL
IS TRADITIONALLY BOTTLED IN TIN.
174
00:10:23,000 --> 00:10:25,620
AFTER THE AUTOMATIC EQUIPMENT
FILLS THE TIN CONTAINER,
175
00:10:25,620 --> 00:10:28,896
WORKERS LOOSELY APPLY
A SNAP-ON CAP,
176
00:10:28,896 --> 00:10:33,206
WHICH THE NEXT MACHINE
PRESSES INTO POSITION.
177
00:10:36,724 --> 00:10:39,241
LAST STOP -- LABELING.
178
00:10:39,241 --> 00:10:41,275
AS THE TIN SPINS,
179
00:10:41,275 --> 00:10:44,103
THE MACHINE WRAPS IT
IN AN ADHESIVE-BACKED LABEL,
180
00:10:44,103 --> 00:10:48,206
NEATLY ALIGNING THE LABEL'S SEAM
WITH THE WELDED SEAM ON THE TIN.
181
00:10:48,206 --> 00:10:53,034
NOW THE OIL'S READY
TO DRIZZLE A RICH WALNUT TASTE
182
00:10:53,034 --> 00:10:57,241
ONTO YOUR PASTA,
GRILLED MEAT OR FISH, OR SALAD.
183
00:11:08,724 --> 00:11:11,551
Narrator: HUMANS HAVE BEEN
MAKING THINGS OUT OF COPPER
184
00:11:11,551 --> 00:11:13,000
LONGER THAN ANY OTHER METAL.
185
00:11:13,000 --> 00:11:15,344
ARCHAEOLOGICAL DIGS
AROUND THE WORLD
186
00:11:15,344 --> 00:11:18,758
HAVE UNEARTHED COPPER VESSELS,
TOOLS, WEAPONS, AND JEWELRY
187
00:11:18,758 --> 00:11:21,448
DATING BACK
AT LEAST 10,000 YEARS.
188
00:11:21,448 --> 00:11:23,137
FAST-FORWARD TO TODAY
189
00:11:23,137 --> 00:11:26,172
AND COPPER IS ONE MINERAL
WE STILL REALLY DIG.
190
00:11:30,068 --> 00:11:32,758
PEEL BACK THE LAYERS
OF MODERN CIVILIZATION,
191
00:11:32,758 --> 00:11:34,413
AND THERE'S A LOT OF COPPER.
192
00:11:34,413 --> 00:11:37,413
IT'S USED FOR ELECTRICAL MOTORS
AND WIRING,
193
00:11:37,413 --> 00:11:39,758
HIGH-TECH GADGETRY AND PLUMBING.
194
00:11:39,758 --> 00:11:44,068
THE METAL KNOWN CHEMICALLY AS Cu
IS ESSENTIAL TO MODERN LIVING.
195
00:11:44,068 --> 00:11:47,413
PURE COPPER
IS RARELY FOUND IN NATURE.
196
00:11:47,413 --> 00:11:51,137
IT USUALLY OCCURS WITH OTHER
ELEMENTS, LIKE IRON AND SULFUR.
197
00:11:51,137 --> 00:11:53,551
TO MINE THE COPPER-BEARING ROCK,
198
00:11:53,551 --> 00:11:57,103
A HUGE DRILL CHEWS
INTO THIS ARIZONA TERRAIN.
199
00:11:57,103 --> 00:12:01,551
IT DRILLS AROUND 130 HOLES
AT LEAST 50 FEET DOWN.
200
00:12:01,551 --> 00:12:04,275
A TRUCK PUMPS EXPLOSIVES
INTO THEM.
201
00:12:04,275 --> 00:12:09,275
IT'S A POWERFUL MIX OF
AMMONIUM NITRATE AND FUEL OIL.
202
00:12:09,275 --> 00:12:12,517
A MINE WORKER LOWERS THE
ELECTRONIC DETONATING DEVICES
203
00:12:12,517 --> 00:12:15,034
INTO EACH OF THE 130 HOLES.
204
00:12:16,896 --> 00:12:21,000
FROM A SAFE DISTANCE AWAY,
HE ACTIVES THE DETONATORS,
205
00:12:21,000 --> 00:12:23,931
STAGING THE EXPLOSIONS
MILLISECONDS APART.
206
00:12:27,931 --> 00:12:30,896
IT'S AN EXPLOSION SEQUENCE
DESIGNED TO FRACTURE
207
00:12:30,896 --> 00:12:35,724
AS MUCH OF THE COPPER-BEARING
ROCK AS POSSIBLE.
208
00:12:35,724 --> 00:12:38,241
SHOVELS SCOOP UP
THE BLASTED ROCK,
209
00:12:38,241 --> 00:12:42,379
LIFTING 55 TO 88 TONS
IN ONE BITE.
210
00:12:42,379 --> 00:12:46,034
THE ROCK IS LESS THAN
ONE HALF OF 1% COPPER.
211
00:12:46,034 --> 00:12:49,793
FREEING THE COPPER FROM IT
INVOLVES DIFFERENT TECHNIQUES.
212
00:12:49,793 --> 00:12:52,931
THE TECHNIQUE DEPENDS ON WHETHER
THE ORE IS IRON-OXIDE-BASED
213
00:12:52,931 --> 00:12:55,034
OR SULFIDE-BASED.
214
00:12:55,034 --> 00:12:58,034
TO PROCESS COPPER
FROM OXIDE ORE,
215
00:12:58,034 --> 00:13:02,344
THEY PILE THE ROCK IN SPECIALLY
PREPARED LEECHING AREAS.
216
00:13:02,344 --> 00:13:05,310
THEY IRRIGATE THE ROCK
217
00:13:05,310 --> 00:13:08,137
WITH A DILUTED
SULFURIC-ACID SOLUTION.
218
00:13:08,137 --> 00:13:10,655
OVER MONTHS,
THE SOLUTION PERCOLATES DOWN
219
00:13:10,655 --> 00:13:12,172
AND DISSOLVES THE COPPER.
220
00:13:12,172 --> 00:13:16,275
THE COPPER SOLUTION
DRAINS INTO A POND.
221
00:13:16,275 --> 00:13:19,862
A PUMP TRANSFERS THIS SOLUTION
TO THE PLANT.
222
00:13:19,862 --> 00:13:21,172
IN THIS CHANNEL,
223
00:13:21,172 --> 00:13:23,482
THE COPPER SOLUTION
BINDS WITH AN ORGANIC AGENT
224
00:13:23,482 --> 00:13:25,551
AND FLOATS TO THE TOP.
225
00:13:25,551 --> 00:13:27,103
THEY ADD AN ACIDIC SOLUTION
226
00:13:27,103 --> 00:13:29,758
THAT INCREASES THE CONCENTRATION
OF THE COPPER
227
00:13:29,758 --> 00:13:32,586
AND MAKES IT
ELECTRICALLY CONDUCTIVE.
228
00:13:32,586 --> 00:13:35,172
THEY TRANSFER
THE COPPER SOLUTION
229
00:13:35,172 --> 00:13:36,896
TO A SERIES OF TANKS
230
00:13:36,896 --> 00:13:40,896
THAT CONTAIN STARTER SHEETS
OF PURE COPPER, CALLED CATHODES.
231
00:13:40,896 --> 00:13:43,517
THEY PASS AN ELECTRICAL CURRENT
THROUGH THE TANK,
232
00:13:43,517 --> 00:13:46,793
AND THE COPPER MIGRATES
TO THE CATHODES.
233
00:13:46,793 --> 00:13:50,000
AT THE OUTSET,
THE CATHODES ARE WAFER-THIN,
234
00:13:50,000 --> 00:13:55,103
BUT OVER A PERIOD OF 10 DAYS,
THEY THICKEN SUBSTANTIALLY.
235
00:13:55,103 --> 00:13:58,689
THEY'RE NOW AN INCH THICK.
236
00:13:58,689 --> 00:14:02,206
EACH ONE WEIGHS
ABOUT 275 POUNDS.
237
00:14:02,206 --> 00:14:06,275
THE PURITY IS NOW 99.99%.
238
00:14:06,275 --> 00:14:09,655
THAT'S IMPORTANT IF THE COPPER
IS TO BE PROCESSED
239
00:14:09,655 --> 00:14:13,000
INTO ELECTRICAL PRODUCTS.
240
00:14:13,000 --> 00:14:17,517
FREEING COPPER FROM THE SULFIDE
ROCK IS MORE DIFFICULT.
241
00:14:17,517 --> 00:14:21,241
IT STARTS IN A MASSIVE TUMBLER,
CALLED A SAG MILL.
242
00:14:21,241 --> 00:14:25,655
INSIDE, STEEL GRINDING BALLS
SMASH WET ROCK TO PIECES.
243
00:14:25,655 --> 00:14:27,206
EXITING THE MILL,
244
00:14:27,206 --> 00:14:30,172
THE SMASHED ROCK TRAVELS
OVER A PERFORATED CONVEYOR
245
00:14:30,172 --> 00:14:32,517
TO SCREEN OUT SMALLER,
PEBBLE-SIZED ROCKS.
246
00:14:32,517 --> 00:14:36,413
THESE SMALLER ROCKS CONTINUE ON
TO DIFFERENT GRINDING MILLS.
247
00:14:36,413 --> 00:14:39,379
THE LARGER ROCKS
CIRCLE BACK TO THE SAG MILL
248
00:14:39,379 --> 00:14:40,862
FOR ANOTHER ROUND.
249
00:14:40,862 --> 00:14:43,517
ONCE ALL THE ROCK
HAS BEEN SUFFICIENTLY GROUND,
250
00:14:43,517 --> 00:14:46,689
THEY ADD CHEMICALS
WHICH COAT THE COPPER PARTICLES
251
00:14:46,689 --> 00:14:48,965
AND MIX IN A FROTHING SUBSTANCE.
252
00:14:48,965 --> 00:14:51,655
THE SLURRY FLOWS
INTO FLOATATION TANKS.
253
00:14:51,655 --> 00:14:53,310
AIR BLASTS CREATE BUBBLES
254
00:14:53,310 --> 00:14:56,551
THAT THE CHEMICALLY COATED
COPPER MINERALS ATTACH TO.
255
00:14:56,551 --> 00:15:00,034
THE BUBBLES CARRY THE MINERALS
TO THE TOP OF THE TANK,
256
00:15:00,034 --> 00:15:02,034
AND THEY OVERFLOW.
257
00:15:02,034 --> 00:15:03,793
AFTER FILTERING THE OVERFLOW,
258
00:15:03,793 --> 00:15:08,517
THEY HAVE A CONCENTRATE
THAT'S NOW 25% TO 30% COPPER.
259
00:15:08,517 --> 00:15:14,758
THEY TRANSFER THE CONCENTRATE
BY RAIL TO A SMELTER FACILITY.
260
00:15:14,758 --> 00:15:18,103
HERE, IT GOES
INTO SEVERAL LARGE BEDS.
261
00:15:18,103 --> 00:15:21,793
EACH ONE IS THE SIZE
OF TWO BASKETBALL COURTS.
262
00:15:24,655 --> 00:15:26,758
THEY ADD SILICA SAND,
263
00:15:26,758 --> 00:15:30,241
CREATING A LAYER CAKE OF SAND
AND COPPER CONCENTRATE.
264
00:15:32,931 --> 00:15:36,034
THE SILICA SAND
IS KNOWN AS A FLUX.
265
00:15:36,034 --> 00:15:37,620
IT WILL SERVE
AS A PURIFYING AGENT
266
00:15:37,620 --> 00:15:41,103
AS THE CONCENTRATE IS SMELTED.
267
00:15:41,103 --> 00:15:43,586
IN THE INTENSE HEAT
OF THE FURNACE,
268
00:15:43,586 --> 00:15:46,103
THE SILICA SAND MELTS
TO FORM A SLAG
269
00:15:46,103 --> 00:15:49,517
THAT ABSORBS THE IRON
AND OTHER UNWANTED MINERALS.
270
00:15:49,517 --> 00:15:52,551
THE SLAG FLOATS UP,
AND THE COPPER SINKS.
271
00:15:52,551 --> 00:15:55,034
ITS PURITY IS NOW 60%.
272
00:15:55,034 --> 00:15:56,724
THEN IT'S INTO A SECOND FURNACE,
273
00:15:56,724 --> 00:16:00,965
WHERE THEY UP THE COPPER CONTENT
TO 98%.
274
00:16:00,965 --> 00:16:04,758
COMING UP, THERE'S MUCH MORE
TO THE STORY OF COPPER.
275
00:16:16,620 --> 00:16:18,620
Narrator:
THERE ARE NETWORKS OF COPPER
276
00:16:18,620 --> 00:16:20,482
IN THE WALLS
OF MODERN BUILDINGS --
277
00:16:20,482 --> 00:16:22,758
WIRES AND PIPES
THAT SUPPLY UTILITIES
278
00:16:22,758 --> 00:16:24,931
AND KEEP THE HOUSEHOLD HUMMING.
279
00:16:24,931 --> 00:16:28,344
HIDDEN BEHIND DRYWALL, IT'S EASY
TO OVERLOOK THE CONTRIBUTION
280
00:16:28,344 --> 00:16:31,344
OF THIS THERMALLY AND
ELECTRICALLY CONDUCTIVE METAL.
281
00:16:31,344 --> 00:16:34,965
BUT BEHIND THE SCENES,
COPPER IS A BIG PLAYER.
282
00:16:38,551 --> 00:16:42,000
WITH THE COPPER
NOW EXTRACTED FROM THE ORE,
283
00:16:42,000 --> 00:16:44,482
THEY POUR THE RESIDUE
ONTO A HEAP.
284
00:16:44,482 --> 00:16:48,206
THIS MOLTEN SLAG FLOWS DOWN
LIKE LAVA FROM A VOLCANO.
285
00:16:48,206 --> 00:16:51,689
AS IT COOLS, IT BECOMES
PART OF THE LANDSCAPE.
286
00:16:51,689 --> 00:16:53,344
MEANWHILE, IN THE SMELTER,
287
00:16:53,344 --> 00:16:56,034
A CRANE DELIVERS
THE FIERY LIQUID COPPER
288
00:16:56,034 --> 00:16:59,379
INTO ANOTHER FURNACE
FOR FURTHER PURIFICATION.
289
00:16:59,379 --> 00:17:01,172
INSIDE THIS FURNACE,
290
00:17:01,172 --> 00:17:07,827
THE PURITY LEVEL INCREASES
FROM 98% TO 99.4%.
291
00:17:07,827 --> 00:17:10,896
THE MOLTEN COPPER
FLOWS OUT OF THE FURNACE
292
00:17:10,896 --> 00:17:12,655
AND INTO ROTATING MOLDS.
293
00:17:16,103 --> 00:17:18,827
THE MOLDS SHAPE THE COPPER
INTO BIG, RECTANGULAR SLABS,
294
00:17:18,827 --> 00:17:20,758
CALLED ANODES.
295
00:17:22,896 --> 00:17:26,620
THE SLABS WILL SERVE AS
POSITIVELY CHARGED ELECTRODES
296
00:17:26,620 --> 00:17:30,310
IN THE ELECTROREFINING PROCESS
THAT'S STILL TO COME.
297
00:17:30,310 --> 00:17:34,862
THAT PROCESS WILL TAKE THE
PURITY LEVEL UP ONE LAST NOTCH.
298
00:17:38,448 --> 00:17:41,448
THE COPPER BEGINS TO COOL
IN THE MOLDS.
299
00:17:41,448 --> 00:17:45,413
A SPRAYER DOUSES THEM WITH WATER
TO SPEED THE COOLING PROCESS,
300
00:17:45,413 --> 00:17:48,310
AND THE COPPER HARDENS
INTO THE ANODE SHAPE.
301
00:17:51,379 --> 00:17:54,931
A HYDRAULIC CYLINDER
POPS THEM OUT OF THE MOLDS.
302
00:17:57,586 --> 00:18:00,068
THEN A CARRIER SYSTEM
RETRIEVES THEM
303
00:18:00,068 --> 00:18:03,517
AND TAKES THEM FOR A RINSE.
304
00:18:03,517 --> 00:18:05,724
THIS GETS RID OF ANY TRACES
305
00:18:05,724 --> 00:18:08,379
OF A NONSTICK SUBSTANCE
APPLIED TO THE MOLDS EARLIER
306
00:18:08,379 --> 00:18:13,206
FOR EASY RELEASE
OF THE COPPER SLABS.
307
00:18:13,206 --> 00:18:14,862
HOOKS FORMED DURING THE MOLDING
308
00:18:14,862 --> 00:18:16,793
MAKE IT EASY
TO RACK UP THE SLABS
309
00:18:16,793 --> 00:18:20,620
FOR SHIPMENT TO A TEXAS REFINERY
HUNDREDS OF MILES AWAY.
310
00:18:20,620 --> 00:18:23,034
AT THE REFINERY,
311
00:18:23,034 --> 00:18:25,517
THE COPPER SLABS SHED
ANY LINGERING IMPURITIES
312
00:18:25,517 --> 00:18:26,862
IN THIS TANK
313
00:18:26,862 --> 00:18:29,655
AS AN ELECTRICAL CURRENT
IS APPLIED.
314
00:18:29,655 --> 00:18:32,344
THE CURRENT CAUSES THE COPPER
TO GRAVITATE
315
00:18:32,344 --> 00:18:33,862
TO THIN STARTER SHEETS.
316
00:18:33,862 --> 00:18:36,172
THE IMPURITIES
FALL TO THE BOTTOM.
317
00:18:36,172 --> 00:18:39,517
THE COPPER DEPOSITED
ON THE STARTER SHEETS
318
00:18:39,517 --> 00:18:42,206
IS 99.99% PURE,
319
00:18:42,206 --> 00:18:46,172
THE PURITY LEVEL REQUIRED
BY WIRE MANUFACTURERS.
320
00:18:46,172 --> 00:18:50,344
THEY LOAD IT INTO A FURNACE
THAT'S ESSENTIALLY A TALL SHAFT.
321
00:18:50,344 --> 00:18:53,379
MIDWAY DOWN,
THE PURE COPPER MELTS
322
00:18:53,379 --> 00:18:56,793
AND FLOWS TO THE BOTTOM
OF THE FURNACE.
323
00:18:56,793 --> 00:19:00,724
FROM THERE, THEY TRANSFER IT
TO AN INSULATED METAL CHANNEL,
324
00:19:00,724 --> 00:19:02,310
WHICH KEEPS IT MOLTEN
325
00:19:02,310 --> 00:19:05,206
AS IT NOW TRAVELS
INTO A VERTICAL MOLD.
326
00:19:05,206 --> 00:19:08,620
THIS MOLD SHAPES IT
INTO RECTANGULAR FORMS
327
00:19:08,620 --> 00:19:10,413
KNOWN AS COPPER CAKES.
328
00:19:10,413 --> 00:19:12,758
COPPER CAKES ARE USED
FOR MANUFACTURING THINGS
329
00:19:12,758 --> 00:19:15,482
LIKE COPPER SHEETING
AND PLUMBING PARTS.
330
00:19:17,862 --> 00:19:20,241
FRESH FROM THE MOLD,
331
00:19:20,241 --> 00:19:22,896
THE COPPER CAKES
ARE ROUGHLY 20 FEET LONG.
332
00:19:22,896 --> 00:19:25,896
A CONVEYOR SERVES THEM UP
TO A CIRCULAR SAW
333
00:19:25,896 --> 00:19:29,172
THAT SLICES THEM TO LENGTHS
REQUIRED BY THE CUSTOMER.
334
00:19:34,724 --> 00:19:38,172
STACKED AND LABELED,
THIS PURE COPPER CAKE
335
00:19:38,172 --> 00:19:41,344
IS NOW READY TO SHIP
TO THE MANUFACTURER.
336
00:19:41,344 --> 00:19:45,206
THEY ALSO PROCESS PURE COPPER
INTO RODS,
337
00:19:45,206 --> 00:19:49,517
A FORM MORE SUITABLE FOR
MANUFACTURING ELECTRICAL WIRING.
338
00:19:51,310 --> 00:19:54,275
MOLTEN COPPER MOVES THROUGH
AN OPENING IN A MOLD,
339
00:19:54,275 --> 00:19:55,758
AND, COOLED BY WATER,
340
00:19:55,758 --> 00:19:58,586
THE COPPER FORMS
A CONTINUOUS RECTANGULAR BAR.
341
00:20:02,482 --> 00:20:04,206
THESE GROOVED ROLLERS
342
00:20:04,206 --> 00:20:06,862
WILL NOW TAKE IT
FROM RECTANGULAR TO ROUND
343
00:20:06,862 --> 00:20:09,379
AND REDUCE THE DIAMETER
SUBSTANTIALLY.
344
00:20:09,379 --> 00:20:12,758
AS THE COPPER TRAVELS
THROUGH THE GROOVES,
345
00:20:12,758 --> 00:20:16,896
IT BECOMES A 3/10 OF AN INCH
THICK COPPER ROD.
346
00:20:16,896 --> 00:20:18,655
THE ROD EXITS,
347
00:20:18,655 --> 00:20:20,137
AND THE MACHINE LOOPS IT
INTO COILS.
348
00:20:23,655 --> 00:20:27,344
THEY LAND NEATLY
ONTO A STEEL SPOOL.
349
00:20:29,724 --> 00:20:32,413
MACHINERY COMPRESSES
THE COPPER COIL,
350
00:20:32,413 --> 00:20:33,758
SQUEEZING IT DOWN
351
00:20:33,758 --> 00:20:37,517
SO IT WILL TAKE UP LESS SPACE
WHEN IT'S TRANSPORTED.
352
00:20:40,655 --> 00:20:45,551
THERE'S ONE LAST SQUEEZE
FROM AN OVERHEAD PRESS.
353
00:20:45,551 --> 00:20:49,241
AND AN EMPLOYEE TIES
THE TIGHTLY COILED COPPER
354
00:20:49,241 --> 00:20:51,241
WITH EXTRA-STRONG
PLASTIC BANDING.
355
00:20:53,862 --> 00:20:56,827
FROM THE EARTH'S CRUST
TO THE FACTORY FLOOR,
356
00:20:56,827 --> 00:20:59,965
IT'S BEEN QUITE A JOURNEY.
357
00:20:59,965 --> 00:21:01,344
SHIPPED TO MANUFACTURERS,
358
00:21:01,344 --> 00:21:04,793
IT WILL NOW BE DRAWN
INTO ELECTRICAL WIRING,
359
00:21:04,793 --> 00:21:08,206
AND THE FUTURE
IS SURE TO BE HIGH-VOLTAGE.
360
00:21:08,206 --> 00:21:11,172
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361
00:21:11,172 --> 00:21:14,137
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362
00:21:21,793 --> 00:21:24,172
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363
00:21:24,172 --> 00:21:27,068
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