Metallurgy

Profitable and convenient extraction of metals

from minerals is metallurgy
Important terms to be used in metallurgy

I Minerals materials
Naturally occurring
containing metals along with the
impurities are minerals

ii Ores Those minerals from which

extraction of metal is profitable
convenient are called ones

ee
Each one is a mineral but each mineral
n
can not be one

CI Native ores
ores which contain metals in elemental
form having physically associated impurities
are native ores

Less reactive elements Au Ag Pt Hg occur

in form of native ores
iv Gangue Matrix
associated with minerals
Earthly impurities
are
gangue
V Flux Impurities added to remove non

fusible gangue are flux

a acidic flux 510215 140101s 13203 s
b Basic flux Argo s Feo s Cao s

selection of flux depends on nature of

gangue
If gangue is acidic basic flux is used
Sio gangue Feo flux Fesioz l

If gangue is basic
acidic used
flux is
D
Cao gangue t 5102 flux Casi Oz l
Based on step of reduction

ore purification

of metal
 ii Native ores of Ag and Ace
o I
OCN t 02 Menz t on
Haotatmpuge
Cag exc
impurities
as residue

Iii Leaching of red Bauxite

Red Bauxite A1203 2420 Fez03 Sia

É Ti
Oz
major
impurity

reaching agent NaOH

Filtrate NaCAL OH tNgsio

an niacin
Red Bauxite D
Residue Fez03 7102

leaching of
11 1Malachite Cuco CucoH
Azurite 26oz CerCOH 2
acid cut ag
Low grade cu ores
bacteria

Cucoz Arlo Hkt 112504 cusoy t coz tho

og
Reduction step
cut ag scrap Fe Cut
Estey

ago t die 112504 Aksoy t tho

soluble

9250469 cud t Cus04

I cutagescut't cu

Cyo t dik 12504 cut cusoat H2O

Physical methods of ore concentration

i Gravity separation Levigation Hydraulic washing

It is based on difference btw density of ore

impurities
Generally metal ores are heavier than impurities

powdered ore is washed by current of running

water
Lighter particles move onwards with
water
leaving behind heavy ore particles

Generally oxide ores carbonate ores and native

ones are concentrated by this method ex Haematite
ii Magnetic separation
It used when one of the ore or gangue
is
is magnetic and other is non magnetic

Powdered one is allowed to pass on a belt

attatched with magnetic roller

magnetic substance makes a new heap and

non magnetic substance make separate heap

c cassiterite t wolframite
I 5h02

Amgen twiggy
ii side Fecz04

Émagnet
Tigre
iii Froth Floatation

Frothfloatiation is generally carried out for

sulphide ones

It is based on different wetting abilities of

mineral and gangue by oil and water

mineral is preferentially wet by oil while

gangue is preferentially wet by water
air

oooot
I Is additives
I E I Frother collector
Froth stabiliser t

actigant
 i

kitano
ggygggt
wgyyygg
i ieyqggea
y.LI

3CO
Frother

It reduces surface tension and supports bubble formation

Also acts as collector

E Pine oil Eucalyptus oil

collector
It adsorbs over mineral surface through its
Polar past so as to make hydrophobic coating
over mineral

commonly used collector sodium ethyl xanthate

engaged.IT TFoErIytaropnilic
Froth stabiliser
St stabilises froth
Aniline Cresol are used as froth stabiliser

Activator
It improves floating abilities of mineral particles
ez also acts as activator for 2ns
 Aesop t 2ns
ÉÉÉ t 2ns og
little exe
cus

By using suitable activators like Naas froth

floatation of oxide carbonates can be carried out

Depressants

They depress floating abilities of undesired particles

is with Pbs
ez Impurity of 2ns found
Naan is used as depressant for 2ns
2ns 4 NaCN Na Cn CCNY t Naas
exo soluble soluble

By adjusting ratio of oil and water depression of

2ns can be done

mineral particles attached with air bubbles float

to surface leaving behind impurities

air bubble collected pressurised H2o

from surface D
m pot mineral
conversion into reducible form
easily
calcination
Preliminary treatmentsRoasting
To remove impurities in volatile form
To convert mineral into oxide

with
smelting slag formation along
melting
Removal of non volatile impurities
usually seduction of metal takes place along
with smelting

calcination
Heating of ore below its melting point in
absence of air or
very limited supply of air
is calcination

calcination is carried out for carbonate ones

sulphate ores Hydrated ores Hydroxide ore

D COZY
ez Cacoz s Cao s

calcite
D
ZnCoz S ZnO S COLT
Calamine
D
Pbs04 s Pbo S 5039
Anglesite
 D
A1203T 21209
Emin

Due to evolution of gases vapours one becomes

porous and hence more reactive due to increased

surface area

organic impurities are also removed in volatile

form
calcination is non redox endothermic
generally

impurities of P As sb are removed in form

of elemental vapours

Roasting
in of excess of air
Heating of ore presence
below its melting point is called roasting

Roasting is mainly carried out for sulphide ores

d
Pbs 02 Pbo t 5029
galena
D
2ns t 02 Zno 5029
 Pbst 02 Pbs04 minor an

Impurities of S P As sb are removed in form

of volatile oxides
St 02 5029
D
Pf 02 140109
D
Ast 02 A52039

Due to evolution of gases or becomes porous

Roasting is redox and exothermic

Smp points

É Roasting of magnetite ore

To reduce loss of iron in form of slag
Fez04 Fez03 Feo

Felt sick fesio slag

gangue
ore roasting s Feroz
Magnetite

Fezo is lets reactive towards sios than Feo

ii Partial roasting of copper pyrite

d
Cafe sa s
Cys Fests

St 02 5029
Fest 02 foot 502
fin p Fesioz slag

If Cuz St 02 920 1 5029

then Fest G20 Feo tags

Fe is more electropositive than cu so

affinity
of Fe is more than a towards oxygen

Partial
a Fe 52 cyst Feo t 5029
gypped Roasting

smelting
calcined s in slag l
t Flux fuel
roasted or furnace
generally
t
can act as
reducer
 molten slag
molten metal one

seduction metal does not

In case
of a of
take place in smelting process

Step 3 Reduction

i carbon based reduction

C or co reducing agent
ÉTxides of Fe en sn Pb are reduced by carbon
based reduction
Fe oxides co is main reducing agent
zn.pb.sn oxides c is
reducing agent
D
Fe203 CO Fez04 t CO2
D
Fezoat CO s Feo t CO2
D
Feo CO Fe t coz
e

Zno t C Zn t CO coz
U

Pbo t c Cot
D Pat cot
Snoot C s Snee
 cu oxides can be reduced by carbon but is
not cost effective

ÉT reduction Auto reduction

self
S2 ion reducer

fief seduction is carried out for sulphide ores of

Cu Pb Hg Sb

Partial roasting is carried out when we have to

use self seduction

Partial
roasting

whole one Two Bortion of ores

then portion is
one
infixed completely roasted with
excess air

p from partial roasting of cafes

T at's 02 D ago 5029
2 0 952 Gai t 5029
l
remaining
 cuts't 02 s attsoE
tasty 95 4 2502
l

Aston Into
Fustat 5 3 25 29

425 02 D Got 5024

a'as't2Éo D
tait 5029
l

Pbs 02 Pbo 5029

Pbstabo 3 Pbt 5029
l

Pbst 02 D Pbs04
Pbst Pbsoy 2Pb t 25029
l

iii Another metal as reducing agent

a 2n as reducer

AgcenzJeag t Zn MCNIFF Agt

lag

AulenlaJcag 2n znccnyjag.pt And

b Fe as reducer
from leaching of low grade a ores
p
outing
tgEeap
s feting t at

c S block metals as reducer

Ting t Na s Ti t Nacl IMI process

Ti dat Mg absentee Ti t togas Kroll's process

gaz
d Al as reducer Thermite reduction
x Al has very high affinity towards oxygen
very high Lattice energy

Al is used for seduction of oxides of Cr man

B

craost Als l
15

Mncs Also Highly

Mp3 Af exothermic
D
3 Bu ago
7 It
Fe is more electropositive than cu so
affinity
of Fe is more than a towards oxygen

Partial
cafe 52 cyst Feo t 5029
gypped Roasting

smelting
calcined s in slag l
roasted ore
t Flux fuel
furnace
generally

can act as
reducer
 molten slag
molten metal one

seduction metal does not

In case
of a of
take place in smelting process

Step 3 Reduction

i carbon based reduction

C or co reducing agent
ÉTxides of Fe en sn Pb are reduced by carbon
based reduction
Fe oxides co is main reducing agent
zn.pb.sn oxides c is
reducing agent
D
Fe203 CO Fez04 t CO2
D
Fezoat CO s Feo t CO2
D
Feo CO Fe t coz
e

Zno t C Zn t CO coz
U

Pbo t c Cot
D Pat cot
Snoot C s Snee
 cu oxides can be reduced by carbon but is
not cost effective

ÉT reduction Auto reduction

self
S2 ion reducer

fief seduction is carried out for sulphide ores of

Cu Pb Hg Sb

Partial roasting is carried out when we have to

use self seduction

Partial
roasting

whole one Two Bortion of ores

then portion is
one
infixed completely roasted with
excess air

p from partial roasting of cafes

T at's 02 D ago 5029
2 0 952 Gai t 5029
l
remaining
 cuts't 02 s attsoE
tasty 95 4 2502
l

Aston Into
Fustat 5 3 25 29

425 02 D Got 5024

a'as't2Éo D
tait 5029
l

Pbs 02 Pbo 5029

Pbstabo 3 Pbt 5029
l

Pbst 02 D Pbs04
Pbst Pbsoy 2Pb t 25029
l

iii Another metal as reducing agent

a 2n as reducer

AgcenzJeag t Zn MCNIFF Agt

lag

AulenlaJcag 2n znccnyjag.pt And

Chromatography

It is based on different adsorption of various

components of a mixture on different adsorbents

Pure metal
Pass Mh adsorbed separately
Fluid
FIE
metal
egg
columns having
adsorbents sympurities are
adsorbed separate

To separate pure metal from adsorbent suitable

solvents are used such solvents Eluents

Lanthanoids are purified by the's method

A1203 adsorbent

Amalgamation
used to purify Au Ag
Impurities
Impure metal Hg e
in
Amalgam of metal
Hgtv C
D

Purmetal
 chemical methods of purification

i Vapour phase refining

Impurities
P suitable A
metal reagent s
gaseous compound
of pure metal
collected separately
heated at
u
higher temp
Hare metal
Reagent
Rittmond's process
used for purification of Ni

is Impurities
Impure Ni t co g
Niccoli gas

Pure Ni

1jm ghg.tk D s volatile iodide

of puremetal
d
puremetal
2
used for purification of Ti Zr Hf B
 Ti Iz Tif U
Impure DD Ti IT
Pure

CI Poling
It is used to purify the metal when it contains
impurities of its own oxides

Green wood source

of
hydygyyy

Impure molten metal is stirred by poles of

green wood
D
azo t cha Cud t coat thot
snort cry s Snl t coat too

Poling is carried out for purification of a fish

III Electrorefining

Impure metal Anode

Pure metal cathode
Electrolyte g compound of that metal t acid
 It
cathode
Anode

Anode
mud
Anodesludge

Anode mud in purification of an contains

Au Ag Pt Pd

Electrorefining is used in purification of Cu Ag Au

2n Pb Hg Al ng Sn

in Oxidative refining
It is used for purification when impurities
present in metal have more tendency to get
oxidised than pure metal
Folatile cupellation
Impure Hot air b'Stympurities process
metal in furnace oxidised non fusible Besse
merisation
slag
Cupellation
cupel Boat shaped Crucible
made of cement or Bone ash

Au are purified from Pb

Ag by this
Bessemerisation
Bessemer converter furnace
e carried out for iron
Fe obtained from seduction has impurities
of si Mn S P C Pig iron
si 02 sioz 1 slag
D
Pt 02 74010 Caz POK z
lag
Ihs
fertilizer
inn 02 Anno
Gudi slag
Ellingham Diagram

consider formation of a metal oxide as

s i
47 429g
s
Mady

for per mole of Oz

MseOy s ii
M s t 02 g
2 y
considering eqbm conditions not much inaccuracyarises
on assuming egbm
DG DA t 2 303RT logQc
0
at eqbm DG Qc Keg
DG 2 303 RT
logkeg
more ire ago per mole 02 more't've key

oxidation of in into annoy more in forward

direction

DG DH TDs

fE.aeatIatIe on Ellingham diagram

For most of metals slope of Ellingham

diagram is t've DS of Manno is ve
Smp points

i indicates
change of slope melting or boiling
of metal or metal oxide
 In given Ellingham diagram temp'T indicates
o

Daoper
mole 02 M Mo

Ti T
a m.pt of M b b.pt of Mo
C b pit of in d decomposition temp of no
ANI B
in s 12021 no s

Mcl 20219 Mo s

Mlg Mocs
t 02cg
MCs 0219 Mo g 1570
i slope ve

ii oxide of an element can be reduced by

another element lying below it in Ellingham
diagram ing ing
Al A1203
DQ
permol
02

T s
BelowTi Above T At T

inghas more oxygen Al has oxygen more Both Alte ing

affinity than Al affinity than ing have equal oxygen
Al is better affinity
so
ing is better so

reducing agent reducing agent

Aotggipatingo ngotai.gs gtaiosMiifitt

iii when curve is extraplotted it will intersect

with Da o line at any temperature Above this
particular temperature oxide will be thermally
unstable Thermal stability comparison of oxides

iv If in process of reduction metal is obtained

in molten state the process is said to be
more effective
M s 20219 MO S
i
an d 120219
fi Mols
is
incestIasi
11531 l
 DI DH
TIG more ve Di towards
more ve

Note That iswhy we carry out calcination or

roasting before melting of Mo to make
reduction step more spontaneous

v C or co as reducer
20151 0219 200191 Ds 0 slope ve
S 0219 02191 15 0 Slope o
220191 0219 2102191 Asko slope t've

o
cos CO2
Da per C coz
mol 02
C co
7180

Above 710 C C is better seducer than co

Below Ho c co is better reduce than c

vi Dao metal to metal oxide formation is

for
less ve than metal to metal sulphide carbonate
sulphate That is why oxide is generally more
easily reducible form
 why metal sulphide are not directly
subjected to carbon seduction
SI 2ms t c 2Mt Csa Griffy
2 MO t C ant CO2 Co

co coz is more volatile than Csa

eco or cos are thermodynamically more stable
than coz
I Metal sulphides are more stable than Csa
 Individual metallurgy of some metals
Cu Pb Zn Sh Al Fe
Ag ing
v imp for
t v imb for
advanced mains

Extraction of Ag from argentite ore

Powdered Froth floateatin concentrated exc ar Naca

ore are
Exc air
sulphide

Fit'd
fesidue
Enema Agconjj
filtrate exc zn y impurities

an residue
Agt
Zn o
Distillation

Ag
impure cupellation
removal of Pb
u impurities
Pure Electrorefining Purer

Ag cathode Ag
Anode impure Ag
euasoeyt.TT
stanogg.gy
purity
É'Itraction of a from copper pyrite one

powdered froth floatatigConcentrated

ore
Partial
roasting

Fesio
slag smelting.tw s F9ts
molten a
matte
abstufemall

slag fesioz
self reduction in Bessemer
si

yertgg.fm c
blister
cu
I 987pure a
Blisteringdue to
evolution of 502

Tough Poling
pitch
copper

electrorefining Pure a
cathode pure an
anode impure an
Anode Ag Au Pt Pd sbTe
Electrolyte Cusof 42504 mad
Extraction of Pb from Galena

powdered Frothfloatation concentrated

in presence of Naca ore

Itimphurentiest Low conchof

impurities
complete
v roasting
Partial
5029 roasting

LPbstPbo
smelting
Tux Caco calculatedamount
D
gangue sick
carbon seduction self
reduction
takes place
I v
slag Casio
sort
Impolite
Pb

fiquation
Purer Pb

Electrorefining
PurePb cathode
impurePb anode
Electrolyte Pbsifothasifftgelatin
Pure Pb
Extraction of zinc from zinc Blende

Powdered Froth flaatation concentrated

or activator cus one

roasting
namblete

molten
impure
2h
q _Zno
Ta Hoo
stylist

Liquation Distill'm Purer an

electrorefining
impure 2n anode
Al Cathode
electrolyte Insat 12504
P se
Extraction of Tin from Cassiterite
Powdered Gravity concentrated
ore one
separation
impfewotsiost
Cust Fes control
roasti

Fesat ask filtrate Snot

Hot fewoft
H2O Aesoat
residue Fesot
zig
small si02
few of

Jay Shoat small sign

smelting
Slag Casio

tags impure
Sn

liquation Poling
Pure Sn a
electrorefining
Extraction of iron From Haematite or Magnetite

crushed Gravity Concentrated calcination

ore one
separation Roasting in
caseof
magnetite
Ennisies
carbon basedreduction

M smelting in blast furnace calcined

rotted
Pig e
flux caco yet coke ore

Slogs
Casi03

piggies.mn.es
wmty

mmg ag
scrap iron ygyg

Puddling process

In Ii form of
purest iron

Y Fe
ye
Rest si man S P
 smelting in Blast furnace

tryy zone of
reduction
zone ofslag
Y formation
zone of fusion
Y
Zone of
combustion

Est
q
zone of combustion max temp zone

Ct 02 CO2 DH LO
2C t 02 220 DH LO
Coste 2 CO DH 0

zone of Reduction Lowest temp Zone

Feroz CO Fez04 t 029

Fezoat CO Feo t 029
Feo CO Fe t coat
spongy
zone of Slag formation
Cacoz Cao t CO29
Cao t sioz Casio slag
gangue

sios t c cot
sit
Mno te s rant cot
pyo te Pat cot
elemental impurities of C si tan Pt mix with iron
Fe oxide c Fet co
if left
zone of fusion
Pig iron melting
slag melting
Fe oxide c Fet co
if left

Pig iron conversion into cast iron

air blast scrap re

molten Pig iron

Ct 02 coat cot Impurity removal

5 02 soap in form of volatile
oxide
 cast iron

Grey cast white cast

iron iron
molten cast iron cooling molten cast iron
fooling
slow
fast
carbon crystallised in form carbon appears in form of
of graphite Grey colour cementite
fgfstoichiometric

softer form Harder form

Puddling process
Iron Pig cast melted in a furnace inside lined
with Fez03 Fez03 act as oxidiser and also as
flux
Feroz t C Fet CO2 9
Feroz Man na not Fe

Fezost si Fe
Fez037Pa
D
1490th 1
I Wnnsio
3 Less
8 slog
After removal of upper slag when iron becomes
semi solid it is removed in form of balls
Balls are hammered and slag is squeezed out
It is called wrought hammered iron

Heat treatment on steel

Quenching
steel D
Red hot
sudden Hardness inc
cooling Brittleness

Angelina red hot

slow softness
cooling inc
Extraction of Al from Bauxite ore

Red Bauxite A1203.2420 Feroz Tiozt si 02

To
impurity

white Bauxite AL03 24207 si 02 mayor impurity

Low grade Bauxite Low Al content

powdered ore concentrating concentrated ore

one inform of Allott
calcination

electrolysis ofmolten Ago

impure
A form in presenceof Alumina
Cryolite NazAIFo or
FluorsparCatz or
both

THerfsprocess

electrorefining
Pure Al

Espnews
 one concentration of Bauxite
Red Bauxite is concentrated by Beyer's process
white Bauxite is concentrated by serpeck's process
Low grade Bauxite is concentrated Hall's process
by
Beyer's process Residue Feroz Tio
Powdered red
Bauxite ore A To Filtrate Nassiost
NaCAlOHA

Al OH31 soin
Huge amount of water
Bettyo pass CO219
Al
addition of freshly
prepared alloy Jagent
seeding

Alas Nan

Yaaffftgge

Alcon It At Alcott zt
At 3 serot
Ammonium salts can be used
for plot of Alcott
from solution containing Alcon 45
CAL OH47 t NHI a Allon13 I t NH3Mt H2O
serpeck's process
Powdered t oke N2 fusion Aln cot sit
white Bauxite

C D Sitt cot
sioat s

Ct Na D ALN t COT
Also

III H2o Allows NHst

Hall's process
Powdered Hsin Na Alost coat Lot
t N9203
Bauxite
s
S
I to
NalAlcon

Alcott zk Huge 41204 cozy

Hall Hero ult's Process
electrolytic reduction

Pure alumina is not used for electrolytic

reduction as
n 20007
is it has very high m.pt
ii it is poor conductor
of electricity

lining
cathode
MÉÉggg
Graphite coke layer
rods
Anode electrolyte
A Lost Catt
NazAlfa

Catz OR NazAlfa or both

inc electrical conductivity of electrolyte mixture
dec m.pt of electrolyte mixture 800 gook

Function of coke layer

o reduces heat loss coke insulator
Prevents oxidation of graphite anode by Oz
viasacrificial oxidation of itself
 Anode cathode
25 ET Ze Alt3 35 Al

Fat A1203 ALF 029

ionic
C 02 CO COLT

Net electrolysis reaction

Agoz t c Al t CO CO2
Don't think that c has reduced
A1203

Hooper's process of electrorefining

cathode
mm
Toplayer pure Al molten

layer Electrolyte
Éom fluoridesof al na Ba

Impure Al molten
Layer i i

hey
i i i i

Anode

on electrolysis Al from bottom layer goes into

middle layer in form of Alt Equivalent
amount of Alt goes into top layer from middle
layer in form of pure Al metal
Anode mud Fe si cu