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Metallurgy Enthuse
Metallurgy Enthuse
Metallurgy Enthuse
by weight
most abundant non metal o
3 Native ores
which contain metal in free form having
ores
oxide ores
Zincite ZnO
Haematite Fe203
Magnetite Fezoiffezostfeo
cuprite Rubycopper Gyo
Pyroleisite Minors
Cassiterite Tinstone 5h02
Chromite Feczoiffeotcrag
colemanite 62136011.5420
Rutile Tioz
Ilmenite Fetiozffeottioz
Bauxite A1203.2420
Bauxite Alcott z 22.0N 5 OCK I
K o Al OH z
A1203 2h20
k I Alofote
Nitrate ores
Magnesite lingcos
calamine 2h03
Cerrusite Pbcoz
siderite Fec03
malachite Cucoz Cu OH z
Azurite Hercog Cu OH z
sulphate ores
sulphide ores
Galena Pbs
copper pyrite Cufesz
l
chalcopyrite aystafests
copper glance GezS
chalcocite
cinnabar
zinc blende 2ns
sphalerite
2 1
Iron pyrite Fesa
fool's gold
Argentite Ages
Silver
glance
Wolframite Few 04 v small Mn wog
classification of Metallurgy
Removal
of impurities from ore
ore concentration
Physical
methods
chemical
methods
Gravity bleaching
separation
magnetic separation
Froth floatation
Leaching
A suitable chemical reagent is added with
Powdered ore ore particles dissolve into
chemical reagent and form solution while
impurities remain insoluble
o 0 tI 2
Na CN t H2O Na t NaOH
Agt 02T Ag
In
CCNk
o o 1I 2
Au t 02 t Na CN t H2O Na Au CN t NaOH
Sdn
Oz oxidiser
Nac N Leaching agent
magnetic separation
It when
is used one of the ore or impurities
is magnetic and other is non
magnetic
Powdered one is allowed to move towards
magnetic zoller and fall downwards
f magnetic magnetic
Froth floatation
It based on difference in wetting abilities
is
of ore and gangue particles by oil and water
Core is preferentially wet oil whileby
impurities by water
carried out the concentration
It is
mainly for
of sulphide ores
Powdered 0kt H2O t Additives In a floatation
cell
Additives
C Frother
Reduce surface tension
EI Pine oil Eucalyptus oil
Act as Collector
stabilise froth
Ii Collector
characteristics of
used to improve floating
core
particles
ee sig Cusoy is used as activator for 2ns
n t Aesop fEn t 2ns 04
Ze
t
Cees
Cii oxide and carbonates can be concentrated
o1ublejL.By
of
adjusting
2ns
of
can
ratio
be done
oil water depression
inner
0k0Pv
YEfoIQQiQQy.q.o
Step Conversion into reducible form
2 easily
Part A Preliminary treatment
calcination Roasting
impurity removal in volatile form
Part B smelting
slag formation along with melting of oselmetal
Removal of impurities which are non fusible
calcination
Heating of core below its melting point in absence
limited air is
of air or
very supply of
calcination
carried out in
reverberatory furnace
calcination is
mainly carried out for carbonateores
Hydrated ores Hydroxide ores sulphate ores
D
Zncoz 2h0 t CO24
Calamine
D
Pbs 04 s Pbo t 5034
Anglesite
D
A1203 2 H2O Al2O3 t 214207
Bauxite
D
Cacoz Cao t CO29
Calcite
organic impurities if present are expelled
out
ore
form obtained after calcination is called
calcined Ose
roasting
carried out in blast furnace
Roasting is mainly carried out for sulphide
ores
D
exe Pbs t 02 Pbo t 5024
Galena
2ns 1 02 3 2h07 5029
inc blende
Gmp point I
Feo t si Oz Fesi
2 3 g gangue tag
Feo
pasifezos
Imp point Ii
Partial roasting is carried out for copper
pyrite one
ore
form obtained after roasting is called
roasted Ose
Smelting
Calcined or roasted
flux fuel 1in furnace
Ose usually
ke
also a reducing
agent
M
t flux Gangue Slagle
e 9h case of F pb.sn oxides seduction
of metal takes place in this step bye
molten slag
molten Lmetallose
Cu oxides be reduced it is
can
by Cleo but no
cost effective
of Pb Cu Hg Sb
one part oxide
sulphide
on
OTHER
dem
Is
Cmetal t
MATER
D
i i Pbs Oz Pbo t 502T
Pbs tapbo D
Pb t 502T
Cremaining
ii Pbs t 02 D Pb504
Pbs t Pb504 D 2 Pbt 25029
Cremaining
ma
D
iii Cigs t 02 Got 50 4
Abs two 6 Cu t 502T
Cremaining
D
iv Alas t 02 CeeO 5029
t
D
Gas two 4 Cut 502T
maining
S 1 202 D
V Cigs04
D
S t
Uys04 4 Cut 25024
Remaining
D
vi Ays t Oz Aesop
was 1 Cus04 Is 3 Cut 25029
Cremaining
as
Znedu Na
then 2 2h Naz ZnCCN t MI
L Sohn
Au Ag
as
t Fe cut treat
Ffedf Eoff rap
reduction
block
meth
by
S
e
H2 is not preferred as seducer in
metallurgy due to its explosive sin with
02 at high temp
Step 4 Purification Refining of metal
Liquation Sm Sb
vapour phase
refining
Distillation Em Cd
teg Hf
Nin Ti Zhi
Fractional
Poling
Sm Cu
Distillation
electrosefining
Si Ge B
zone
refining
chromatography Lanthanides oxidative
Ag All Refining
Amalgamation
Liquation
It is impurities present with metal
used when
have higher melting point than pure metal
is
Metal e
Impure metal
impurities
s
Distillation
metal like 2h Cd Hg are separatedfrom
non volatile impurities by this method
Fractional distillation
Zn b s 920 C
Cd 5 767 C
Zn t Cd Fe Pb alloy
Fe Pb bibs 1500 C
usity
Di cdCo
tmbu
gzo.CI 7767 F 2h t
fee Pb
U
S 12h
T 920 Fe Pb
jamb
Zone refining fractional crystallisation
It is based on nose solubility of impurities
in molten metal than in solid metal
Pure metal
crystallises while
impurities pass on to adsacent
molten zone
e wetsapurification
carried out for
e
si
semiconductors
chromatography
Amalgamation
Impure add Hgce impurities
Ag AU metal amalgam
Ag Hgf Au Hg
natives Distillation Hgt
Heptad
Poling
Impure metals having their own oxide as impurity
are purified by this method
Green wood
to
poles
molten
Impure metal
cu.sn purified by this method
Alzo t Cud t C029 t H2O
5h02 t CHq Snf t cost H2O
reducing
agent
Electrosefining
used for purification Ag Au 2h Pb Sn Al Cee
Pure metal cathode gmpuse metal Anode
Electrolyte Metal salt theandated
no Insoluble impurities settle down below anode
known as Anode mud
Au Pf Pd
ee Cee Ag
Anode mud
oxidative Refining
Applied when impurities are more readily
oxidisable than pure metal cupellation
8asTJ
mmeekutdeHIFF
nimpusie.es
oxidised flux
Put into furnace
cupel gag
Besemerisation
µ
Crucible
Bessemer convest
Bessemerisation
used for Iron Cu
Iron obtained from seduction step is called
iron
Pig P
Impurities of S si Mn
St Oz 5029
5
sit 02 sioz slag
D
Mnt 02 Mroz slag
Pat 02 pyo xjsCaz 1004 z
Thomas
Slag
used ag I
fertiliser
Ellingham Diagram
consider the oxidation of metal by Oz
RM Mx Og S i
2 02
s t g
for per mole of Oz
Ii
2yd MIS t 02cg g Mn OgCs
DG peamole 02 DH D8Tw
x axis
eahtigngt.am Y
axisg inteygsepoe
ope
D5
For most of metals 0 slope is
positive
i change in slope of curve indicates phase
transition i e corresponding temperatures
indicate melting lot or boiling point of
metal or its oxide
Lii A metal oxide can be reduced by an
element lying below it in Ellingham diagram
G Go
In F EO
DG
permole
of 02
Tik
T
Below Ti Above Ti At Ti
C as seduces
µ or co
a co coz
DG
permole
coz
02 co
710 C
T
Froth
floatation
v
conceonterated
Partial
roasting
FeO t 5029
flux sick
smelting
Slag fesig
Matte
self seduction
in bessemer
converter
flux si 02
Blistering Blister_ g8 ou
due to
copper rest impurities
502 evolution
Poling
T0Efppeeie
Electrosefining
Ruse Cu Cathode
impureCu Anode
Acidified Cusoye electrolyte
TJArnnouddeiAgiAuiPt.Pd
qqn984opuc
cupellation NS.CZNCCN4
Cfiltrate
Ag
I Electrosefine'T pyreA
Pyre Ag cathode
impure Ag Anode
Agnosttenos Electrolyte
Extraction of Al from Bauxite Ose
e
Bafgxe.it conogeentinatepdm
of Alto Hb
calcination
v
i.mpu.se
Al
Electrolytic reduction in A1203
presence of cryolite alumina
CNazAIFo
Fluorspar Catz
Hall Hero vet's process
Electrosefining by present t
Hooper's process
itsiieswYteeted
ftp.t.ae
at bottom
Anode mud
on concentration
conch
Red Bauxite Berger's process
conch
white Bauxite Serpeck's process
Bauxite cone Hale's process
low grade
Beyer's process
Red Bauxite Bauxite having Feroz as
chief impurity
Residue
A1203 2h20 t Fez03T NaOH CFezozt Tick
D
Siozt Ti Oz
filtrate
NaCAlL0H74JiNazSiO3eCAeLoH4JCteu
Carsom
YID
8eeaH20ata.d Allotebt
Cwhite
freshly preparedas A1203 H2O
loft of Al Hb
seeding agent
of be
NHI salts can used in place of
CO2
Alcott I t NHI Al 1014131 t NHzTt H2O
Serpeck's process
white Bauxite Bauxite having sick as
Hall's process
for Low grade Bauxite
fusion
Bauxite
S
t Na2C03 Na Al Oz 1 COLT
s
H2O
Cst water Nat
All 0h13 I Alcott 4J
og som
Poor conductor
of electricity
Naz AlFG Katz
and Cor fluorspar are added to
cryolite mixture has
A 1203 The formed
lower melting point and increased
electrical conductance
Graphite mr
Anode I
Fe tank
or steeltank
agey 0
mm
oooo
g I
II eassmomagning
f II
Hf I
f
electrolyte
AKO zt
NazAIFG Catz A1203 INazAIEt.GE
60 20 20 ratio
NazAIFg 3 Naf t Al Eg
A node cathode
2E Fat 2E Alstt 3e Al
Al20ztFz AlEgt029
ionic
coke layer5102 co coz
eh
Abozt cokelayer B c Alt Colcord
overall electrolysis pin
Ako z is not being seduced by
carbon
Role of coke layer
to seduce
i
sacrificial oxidation of itself
loss of graphite anode
2 Reduces heat loss insulator
Hooke's process
electrosefining
Al
of
Ocathode
om
mpouttema
Alt3 A1 molten
Fluorides
of Na Al Ba
electrolyte
Al SAT molten
dEEeinsity
impure
Al
theeto
Anode
3
Al
from anode oxidises into Alt and
goes into middle portion electrolyte
Equivalent amount of Art from
middle layer undergoes seduction into
A1 and rises to top layer
fe cu si collected
Impurity of are
in bottom anode mud
Extraction of 2n from Zina Blende
2ns
efiistidfiation smelting in
2h Blast furnace
spelter
zinc
carbon reduction
Electrorefining Pure
In
Extraction of Pb from Galena Pbs
Galena
frothfloatation
in presence of NacN
impurityanchored
when when
are high are impurities
less
complete
roasting partial
Pb roasting
Pbs 1 Pbo
smelting in
Blast furnace as
dself
carbon reduction
flux Caco3 seduction
Impure Pb Impure
Pb 1 Sgt
s1tg Casioz
Liquation
PuserPT Anode impute Pb
Cathode Puse Pb
Puse electro sefine.mg
Electrolyte PbSiFgtHzsiFg
Pb
Extraction of iron From Haematite or magnetite
calcined1pigi
V
esemmettai7einc.b.EE roasted
slag ox
Casio
Fe
295
2 3y C
l Z l Mm si P S
e
Puddling process
wiforkhtQpureqst.IM
ggy.pe
fy C
traces of Mn si P S
smelting in Blast furnace
m.o.iaaiamii.i.is
Zone of combustion
Ct 1202 COT
lg DH LO
I p
Zone of Reduction
Fezozt CO Fez04T COLA
Fez04T CO Feo 1 CGT
Feo co Fe 1 COLT
Fez03 t co Fe t CO2 resale RM
spongy
Zone of stag formation
D
Cacoz Cao COLT
caotfgd.gg Casio3cslag
sick t c a si cot
Zone of fusion
iron si nnn P
containing impurities c S
melts and collected at bottom of furnace
iron melt
pig air blast
impurities convert into oxide form
Ct 02 C 0 029
stoat sort
cast iron
Puddling process
In a
furnace lined inside with Fea
iron is melted
Pig ironfast
Fezog lined act as oxidiser for the impurities
present in pig iron or cast iron also act as flux
Fez t c feet cold
D
Fet Tano
IS n.s
3
EEE retsioaO McnsEigg3
FezOgtPq Fe t 104010
B fepoyscag
when
After removal of upper slag layer
molten iron becomes semi solid it is taken
out in form of balls and then hammered
to squeeze out the slagremaining
wrought iron is the purest form of iron
qqqng
softness
g smelting Ket
flux Cac limited
Casioscslag
Liguation
Poling pu 8Pu
s
as
I
j
Cnagnesile
x Electrolysis
D D
Goln
Desilverisation of Argentiferous Lead
Pbt
having
impurity of Ag
Parke's process
Pb
Distillation 2h10
Ent Ag
separated Ag
from Pb
cupellation
Pattinson's process Pb
semiedjagrich
cool iq cooling AgtP
molten argentiferous t Eutectic
solid mixture
Leed pb of 97.44 Pbt
2 GY
Pb MP 327 C Pb crystal
Af M P 303 C 34
jetty
432
filter
ppt
crystals
Aiotten Pb
tracesofPb
Icupellation
Pb can beremoved