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1 Metallurgy SB 2023

Metallurgy is the extraction of pure metals from their ores. Some key steps include mining, concentration of the ore, smelting to separate the metal from gangue, and refining processes like distillation or zone refining to further purify the metal. Common concentration methods are gravity separation, froth flotation, magnetic separation, and leaching using techniques like cyanidation, alkali or acid leaching. Smelting uses processes like oxidation, reduction, and slag formation to extract the metal. Refining such as liquation, distillation, or zone refining produces high purity, marketable metal.

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62 views39 pages

1 Metallurgy SB 2023

Metallurgy is the extraction of pure metals from their ores. Some key steps include mining, concentration of the ore, smelting to separate the metal from gangue, and refining processes like distillation or zone refining to further purify the metal. Common concentration methods are gravity separation, froth flotation, magnetic separation, and leaching using techniques like cyanidation, alkali or acid leaching. Smelting uses processes like oxidation, reduction, and slag formation to extract the metal. Refining such as liquation, distillation, or zone refining produces high purity, marketable metal.

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Bella Cakie
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METALLURGY

PERIODIC TABLE
DIFFERENCE BETWEEN METALS AND NON METALS
METALLURGY

• Art of extracting pure metal from its


chief ore
Metals which can exist in free state

• Copper
• Silver
• Gold
• Platinum
Mining

• An economic activity related to excavation of


earth to extract commercially valuable
minerals
Mineral

• A naturally occuring substance obtained by mining


which contains the metal in free state or in the form of
compounds like oxides, sulphides, carbonates,
sulphates, etc
ORE

• It is defined as the mineral that contains a


high percentage of metal, from which the
metal can be conveniently and economically
extracted
• Clay - Al2O3.2SiO2.2H2O
• Bauxite - Al2O3.2H2O
• All ores are minerals but all minerals are not
ores
TYPES OF ORES
GANGUE OR MATRIX

• The non metallic impurities, rocky


materials and siliceous matter are
collectively called gangue or matrix
FLOW DIAGRAM FOR METALLURGICAL PROCESS
(GENERAL)
CONCENTRATION METHODS

1. Concentration refers to removal of gangue

2. Nature of ore, type of impurity and environmental factors


decide method used for concentration of ore
GRAVITY SEPARATION PROCESS
(HYDRAULIC WASHING) – OXIDE ORES
1. Ore has higher specific gravity (oxide ores like Haematite
Fe2O3 and Tinstone SnO2) whereas impurity has lower specific
gravity
2. Finely powdered ore is washed with water and lighter
impurities are washed away leaving behind heavier ore
particles
FROTH FLOATATION PROCESS – SULPHIDE ORES
(like PbS, ZnS)
Frothing agent – Pine oil,
Eucalyptus oil
Collectors – Sodium ethyl xanthate
(they enhance the non
wettability of the ore particles)
Froth stabilisers – Aniline,
Cresols
Depressants – NaCN – acts as
a depressant for ZnS but not
PbS – ie when a mixture of two
sulphides are present - NaCN
selectively reacts with ZnS to
form Na2[Zn(CN)4] and prevents
it from forming froth. So PbS
ELECTROMAGNETIC SEPARATION PROCESS

To separate tinstone (non-magnetic ore)


from Wolframite (magnetic impurities)

Similarly Ores of iron like


Chromite, Pyrolusite which are
magnetic can be separated from
non magnetic impurities like
silica, etc using magnetic
separation
Leaching
• This concentration method (chemical method) is based on
difference in solubility
• The ore particles dissolve to form soluble salt or complex
whereas impurities (gangue or mixture) remain
undissolved and can be separated.
• Used when ore is required in high degree of purity
Cyanide leaching
• Used for metals like gold
• Gold is leached with aerated dilute solution of NaCN
• Gold forms a soluble cyanide complex leaving behind the
impurity (aluminosilicate)
• Gold is recovered from the complex by reduction
(displacement) with zinc
Alkali leaching
• SiO2, iron oxides and TiO2 - impurities present in bauxite
• Bauxite is dissolved in hot conc. NaOH solution
• Al2O3 and SiO2 dissolve in NaOH to form sodium meta aluminate and sodium silicate
leaving behind impurities (iron oxides and TiO2) which are filtered and removed
• Al2O3 + 2 NaOH + 3 H2O → 2 Na[Al(OH)4]
• SiO2 + 2 NaOH → Na2SiO3 + H2O
• CO2 is bubbled through the solution containing sodium meta aluminate and sodium
silicate and seeded with freshly precipitated Al(OH)3
• Na[Al(OH)4] + CO2 → NaHCO3 + Al(OH)3↓
• Al(OH)3 precipitates out leaving behind Na2SiO3 in solution
• Al(OH)3 precipitate is filtered and strongly heated at 1473 K to obtain pure alumina
• 2 Al(OH)3 → Al2O3 + 3 H2O
Ammonia leaching
• Ore containing Ni, Cu, Co treated with aqueous ammonia
where soluble complexes of above metals [Ni(NH3)6]2+,
[Cu(NH3)4]2+, [Co(NH3)5 H2O]3+are formed leaving behind
the impurities like gangue, oxides and hydroxides of iron
(III) and aluminosilicates

Ni2+(aq) + 2 NH3(aq) + 2 H2O(l) ↔ Ni(OH)2(s) + 2 NH4+(aq)


Ni(OH)2(s) + 6 NH3(aq) ↔ [Ni(NH3)6]2+(aq) +2 OH-(aq)
Acid leaching
• Used for sulphide ores like ZnS, PbS, etc
• Ore is leached with hot aqueous sulphuric acid where
insoluble sulphide is converted to soluble sulphate and
elemental sulphur
OXIDATION
CALCINATION AND ROASTING
REDUCTION
SMELTING
Reduction occurs in two regions
Upper region: Fe2O3 + 3 CO → 2 Fe + 3 CO2
Fe3O4 + CO → 3 FeO + CO2
Middle region: FeO + CO → Fe + CO2
SLAG FORMATION ZONE
Limestone decomposes to produce

CaO which combines with silica (SiO2)

CaO + SiO2 → CaSiO3


BESSEMERISATION
• Matte is a mixture of Cu2S and some amount of FeS
• Transferred to Bessemer converter
• A blast of hot air and silica are blown through molten
matte
2 Cu2S + 3 O2 → 2 Cu2O + 2 SO2
2 FeS + 3 O2 → 2 FeO + 2 SO2
FeO + SiO2 → FeSiO3
2 Cu2O + Cu2S → 6 Cu + SO2
• The product obtained is Blister Copper (98%)
REDUCTION BY CARBON
• Applicable to elements which do not form carbides at the
reduction temperature
• ZnO(s) + C(s) → Zn(s) + CO(g)
REDUCTION BY
HYDROGEN
• Applicable to oxide of metals like Fe, Pb, Cu having less
electropositive character than hydrogen
• Ag2O(s) + H2(g) → Ag(s) + H2O(l)
REDUCTION BY METALS
• Cr2O3+ Al → 2 Cr + Al2O3
AUTOREDUCTION
• Simple roasting gives the crude metal
• A separate reducing agent is not required
• HgS + O2 → Hg + SO2
REFINING

• Distillation
• Liquation
• Poling
• Zone refining
• Mond’s Process
• Van Arkel Process
Distillation
• Used for low boiling volatile metals
• Zinc (b.p. 1180 K) and mercury (630 K)
Liquation

• Used in case of low melting metals like Zn (419.5 0C) &


Pb (327.5 0C)
• Impure metal placed on the sloping hearth and heated
above its melting point
• Metal melts and flows down the slope leaving behind
high boiling solid impurities
ZONE REFINING
• Used when metal is required in high degree of
purity
• Employed for semiconductors – Si, Ge & As
• Based on fractional crystallisation – pure metal
crystallises out leaving behind impurities in
molten region
MOND’S PROCESS
• Used for nickel
• Impure nickel (Fe, Cr) is heated with
carbon monoxide where nickel alone
forms volatile carbonyl leaving behind
impurities at 330 – 350 K which on
heating to about 450 – 470 K decomposes
to give pure nickel
330-350 K 450-470 K
Ni + 4 CO Ni(CO)4 Ni
VAN ARKEL PROCESS
• Employed for Ti and Zr
• Impure metal is heated with iodine – only
Ti and Zr form volatile iodides which on
heating decomposes to form pure Ti or
Zr
525 K 1675 K
Ti + 2 I2 TiI4 Ti + 2 I2
tungsten
f ilament

870 K 1800 K
Zr + 2 I2 ZrI4 Zr + 2 I2
tungsten
f ilament
COLUMN CHROMATOGRAPHY
ORES OF ALUMINIUM

• Bauxite - Al2O3.2H2O
• Cryolite – Na3AlF6
Leaching – Gold/Silver

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