Non ferrous extractive metallurgy

Introduction:
Ore:

Bauxite Galena

An ore is an occurrence of rock or sediment that contains sufficient

minerals with economically important elements, typically metals, that
can be economically extracted from the deposit.
 Mineral:

Quartz

Minerals are naturally occuring, inorganic,crystalline solids having a

definite chemical solids having a definite chemical composition and
characteristic physical properties.
Mineral resources of non ferrous
metals in India:

Adequate to Inadequate
Abundant

Poor
 Mineral resources of individual
elements:
Aluminium(Al):

Bauxite ore
Non-ferrous Industries in India
 Aluminium Industries:
Companies under the India aluminium industry:
• Hindustan Aluminium Company(HINDALCO)
• Indian Aluminium Ltd(INDAL)
• National Aluminium Company(NALCO)
• Bharat Aluminium Co.(BALCO)
• Madras Aluminium Co.(MALCO)
Extraction of Metals from Oxide
ores
Extraction of Aluminium
 Contents:
Ores of aluminium
Uses and properties
Purification of bauxite- Bayer’s process, factors affecting
Bayer’s process
Extraction of aluminium from alumina- Hall heroult
process , anode effect
Refining of aluminium –William Hoop’s process
 Aluminium:

Symbol: Al
Density: 2.7 g/cm³
Atomic mass: 26.981539 u
Melting point: 660.3 °C
Atomic number: 13
Properties of Aluminium
Electrical &
Light thermal
weight conductivity

Impermeable Corrosion
& Odourless resistance

Ductile and
Recyclability
malleable

Did you know????

Reflects 92% Light
Transportation Construction
Applications of Aluminium

Electrical Consumer goods

 Ores of Aluminium:

Bauxite
Diaspore - Al₂O₃ .H₂O

Did you
know????
Most abundant
metal

Gibbsite – Al₂O₃.3H₂O
Extraction for Aluminium

Bauxite ore

Alumina
(BAYER’S
PROCESS)

Aluminium
(HALL HEROULRT PROCESS)
 Bayer’s process for alumina
production
Bauxite
Heat exchange Effluent
Crushing Grinding classification +100#
Cooled
liquor

Leaching Caustic soda solution

Precipitation
Steam
Pregnant liquor
Thickening
Settling Red mud
Al₂O₃ hydrate
Starch
Washing Hot liquor
Rotary kiln

Anhydrous
alumina
 Factors affecting Bayer Process:
. • Finer bauxite gives better digestion of alumina in liquid
liquor.
• Wet grinding is more efficient than dry grinding.
• Digestion accelerates at high temperature above 100⁰C.
• At low temperature below a limit cause lost of alumina. So,
maintain the temperature at about boiling point of water.
• Sensible heat of recovered from hot liquor by heat
exchangers.
• In precipitation stage, entire precipitates of alumina not allow
because it may cause precipitation of silica along with alumina.
• For efficient calcinations of alumina in rotary kiln at 1400⁰C
to give anhydrous alumina.
Hall Heroult process
Bus bar
Synthesis of Cryolite
Electrolytic Reduction of Cell
Anode effect
 Factors affecting anode Effect:

• Nature of electrolyte: Anode effect occurs most

readily with fluoride and least with iodides,
Bromides and Chlorides required large critical
current density than iodide, fluoride both.
• Purity of electrolyte: Greater purity lower in
current density and vice verse.
• Type of electrolytic Anode: The cryolite -
Alumina melt anode effect at 4-5 amp/sq. cm. when
C anode used and 7-8 amp/sq. cm. for graphite
electrode.
• Temperature: Increase in temperature reduces the
current density.
 Causes of Anode Effect:

• Thermal Effect: Local overheating can lead formation

of gaseous film which deposits anode from electrolyte.
• Electrostatic Causes: During electrolysis, gas bubbles
form which is electrically charged. The charge may be
originated from the anions discharged at the boundary
of newly form gas bubbles at high current density. So,
gas is partly ionized when gas bubbles acquires
opposite charge to that electrode i. e. negative charge
there will be formation of adherent gaseous film which
could separate the molten electrolyte from anode.
Electrolytic refining of aluminium
 Alumina Plant at Hindalco

Leaching of Bauxite(HINDALCO)
Aluminium industries in India &
capacity:
 Aluminium industries in India &
capacity:
Company (Location) Capacity (in Mtpa) Production (in Mtpa)

FY 16 FY 17

HINDALCO 1.32 1.23

NALCO (Angul) 0.50 0.46

BALCO (Korba) 1 3.45

MALCO (Mettur) 0.4 0.295

VAL (Jharsuguda) 1.6 0.5

TOTAL 5.935
Future demand of aluminium:
Extraction of Tin
 Contents:

Uses of tin and its properties

Ores of Tin
Extraction of Tin-ore concentration , smelting and
refining
 Tin:
Symbol: Sn
Melting
point: 231.9 °C
Atomic number: 50
Atomic mass: 118.71 u
 Properties Tin:
Melting Soft and
point: malleable
231.93⁰
C Excellent
Boiling
point: Corrosion
2602⁰C protection

Ductile
Silvery
white
Durable
 Uses of Tin( Sn ):

Bronze Tin cans

Soft solder Spraying

decoration
Common ore of Tin:

Cassiterite
1.Concentration of tin ore

Gravity separator
 Smelting of Tin:

Reverberatory furnace
 Refining of Tin:
•Various metallic impurities such as copper , lead , iron , arsenic etc.
Are contained in most of the tin produced in smelting concentrate and
slag . Those impurities , which are reduced with the tin in the course
of smelting , must be removed before the tin is marketed.
•Necessary refining is accomplished by the methods discussed below:
refining process impurities removed

Liquation Fe, As, Cu

Blowing or tossing Fe, Al, Zn, Ni
Treatment with sulphur Cu
Treatment with aluminium Sb, As , Cu, Ni
electrolysis Pb, Sb, As, Cu, Bi , Ag
 Liquation or sweating:
Liquation process of refining: this method is used for
purification of such metals which contains impurities whose
melting point is lower than the impurities.
 Boiling or tossing of tin:
• In boiling , the molten first-sweat tin is stirred with poles of
green wood, producing a strong bubbling or boiling action . The
metal impurities and some of the tin are oxidised during this
poling process and are skimmed off in the form of an oxide
dross.
•When tossing is used instead of poling, hand ladles of molten
tin are poured from a height back into the kettle , thus exposing
the tin to the oxidising action of the air.
•Boiling or tossing is continued until the operation yields the
desired grade of refined tin , which is then cast into pigs for
marketing.
 Electrolytic Refining of Tin:

Pure Tin metal Impure Tin metal

cathode anode

Mixture of cresol
sulphonic and
sulphuric acid
solution