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Subject Chemistry

Paper No and Title Paper 4: Environmental Chemistry

Module No and Title Module 30: Environmental issues of Metallurgy

Module Tag CHE_P4_M30

Chemistry Paper 4: Environmental Chemistry

Module 30: Environmental issues of Metallurgy
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TABLE OF CONTENTS
1. Learning outcomes
2. Introduction
2.1.Metallurgy
2.2.Uses of metallurgy
3. Environmental issues of metallurgy
3.1.Evolution of toxic gases
3.2. Air pollution due to dust, fumes and smokes
3.3. Waste disposal or recycling problems in mineral industries
3.4. Cases of environmental impact of metallurgy
4. Prevention methods
4.1 Recycling of metallurgical wastes
4.2 Improving the technology
5. Indian prospects
6. Summary

Chemistry Paper 4: Environmental Chemistry

Module 30: Environmental issues of Metallurgy
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1. Learning Outcomes
After studying this module, you shall be able to

• Know about the term metallurgy and its uses.

• Learn about the process involve in metallurgical industries
• Identify the problems caused by metallurgical processes and its effect on human health.
• Evaluate the solutions or prevention techniques in order to protect the environment.

2. Introduction

2.1 Metallurgy

Metallurgy is a science that study about the physical and chemical behavior of metallic elements
and their mixtures. It is a method of production of metal components which can be further
manufactured or consumed. It is also a study of properties of metal on the basis of which they
combined to form alloy.

Fig.1 The process involves in Metallurgy

As shown in Fig.1 metallurgy involves three processes. In the process of concentration of ores in
which breaking down of large pieces of ores take place and then the valuable particles are
concentrated by removing waste particles. Ore may contain more than one valuable metal. They
can be separated into individual constituents. The concentration of ores can take place either
physically or chemically.

Chemistry Paper 4: Environmental Chemistry

Module 30: Environmental issues of Metallurgy
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Physical process involves the separation of waste minerals by magnetic separation, Hydraulic
washing and float floatation method. On the other hand chemical process involves leaching for
the concentration of ores. The other two processes of metallurgy are conversion of concentrate to
oxide and refining of metal. Roasting and calcination are two methods which take place in the
conversion process. And refining of ores involves liquation, electrolysis and distillation process.

2.2 Uses of metallurgy

The metallurgy process is employed for extraction of metals, which have very high melting
points. Due to their higher melting point, it is easier to form solid parts of these metals and even
convert into powder and subsequent pressing the powders into solids. For example, powder
metallurgy plays an important role in the formation of tungsten filaments for electric light bulb.
Some of the waste materials such as iron and steel slags are used in the manufacture of cement
and construction of roads. The processes are applied to metals and alloys, in order to change their
shape, to alter their structure or composition, or some combination of these. Small parts for
automobiles and appliances are the most common applications of metallurgy.

3. Environmental issues of metallurgy

The metallurgical activities are the cause of environmental problems such as air, water and land
pollution due to the generation of a large number of hazardous wastes. The process of extraction
of metal increases day by day which results in the production of waste material and pollutants.
The production has increased greatly in recent years. Due to increase in production, the lands
which are nearer to the industries get affected and are not fit for farming. The particles emitted
also cause danger to vegetation and animal life in the nearby area.

Fig.2 Waste disposal problems in the mineral industries

Chemistry Paper 4: Environmental Chemistry

Module 30: Environmental issues of Metallurgy
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The problems caused by metallurgical industries are characterized on the bases of nature of their
effects it includes the followings issues.

3.1 Evolution of toxic gases

The gases produces by metallurgical industries adversely affect the human health. As per mining
process is concerned, it causes the waste rock to accumulate on the surface of the ground which
covers many acres of land. And heavy wind causes dust storms in local area. The process
produces noxious gases such as, NO and NO2.

NH4NO3 → N2O + 2H20

Mining of radioactive ores causes liberation of radioactive gases which is hazardous to human
health. The waste water produced during the mining process has ammonium ions which are
reduced by microorganisms to NH3 and are toxic in nature.

3.1.1 Inhalation of toxic gases

Inhalation of toxic gases causes poisoning. Some gases are very dangerous if breathed
continuously or if breadth in higher concentration as they contain noxious fumes or toxic dusts.
Gases like SO2 cause irritation like excessive flow of saliva as well as eye and respiratory
irritation. Other gases such as acetylene cause asphyxiation. Which means if the gas is present in
higher concentration in air it causes death without other significant physiological effects. Also,
Carbon monoxide causes a special case of asphyxiation as it impairs the vascular oxygen
transport. It is estimated that only 0.1 % of CO in air is enough to kill a person in few minutes by
asphyxiation.

Leaching process results in the generation of explosive and poisonous gases as the components of
slags react with water. Such as, carbide produces methane (CH4), nitride forms ammonia (NH3)
and phosphorus results in the formation of highly toxic phosphine gas (PH3).Because of the
soluble residues and the hazardous gas evolution, the salt slag cannot be simply dumped.

3.1.2 Explosion and Fire Hazard

While handling gases, vapors and molten materials such as molten salts, slags, metals explosions
may take place in metallurgical industries. As when these molten materials come in contact with
water, explosion takes place. While it is safe to pour molten slag or molten metal into water for
cooling purpose but the reverse is not true. Molten mattes are dangerous to contact with water
because of the formation of H2S which is explosive.

In underground coal mines natural gas is the cause of explosion it may also present in other
mines. Also aluminum or iron powder may catch fire if undergoes oxidation. Some
microorganisms catalysis the oxidation reaction and generate heat which turns into explosions.
Table 1 shows different metallurgical industries and its pollutants.

Chemistry Paper 4: Environmental Chemistry

Module 30: Environmental issues of Metallurgy
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Table 1 Pollutants of metallurgical industries

3.2 Air pollution due to dust, fumes and smokes

Chemical reactions take place in the metallurgy process results in the formation of fumes and
smokes while dust is formed by mechanical attrition. The inhalation of dust causes lungs
problems by hardening the parts of the lungs. Dust like asbestos cause cancer as it causes damage
to lungs as well as other parts of the body. Fumes and smoke are more dangerous than dusts
because of their small size and the ease with which they can enter the respiratory system of body.

3.3 Land pollution caused by mining process

Mining is the process by which the extraction of valuable takes place from the earth. It involves
basically the extraction of those minerals which cannot be made artificially or are non-renewable
resources. But the process can be the cause of many environmental problems which includes soil
erosion, formation of sinkholes, loss of biodiversity and pollution in soil groundwater and surface
water.

3.3.1 Tailings

Tailing is basically the material which is left after the separation of valuable material from the
ores during the mining process. It includes the waste rock. In mining process pulverization of ores
take place in which the extraction of minerals from ores done by converting them into fine
particles, so tailings are typically small in size. Mine tailings are usually produced from the mill
in slurry form.

Chemistry Paper 4: Environmental Chemistry

Module 30: Environmental issues of Metallurgy
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Disposal of mine tailings is one of the most important environmental issues. The tailings are
made up of gangue materials. They commonly contain non-mineral sulfides that can break down
and release metals and generate acidic conditions. In addition to this, some methods involve
marine pollutants such as copper sulfate and cyanide which is present in the tailings.
Several major environmental disasters caused by tailings include dam failures and other release of
tailings into the environment. The Teri environmental disaster and the Buffalo Creek Flood are
the examples of disaster caused by tailing of mining.
3.4 Waste disposal or recycling problems in mineral industries

Ores which are obtained by mining process are purified by removal of unwanted components
known as gangue minerals. It has a large disposal problem as it contains pyrites which undergoes
oxidation and generate sulfuric acid when exposed to air or moisture.

Recycling of various metallurgical slags produced in the metal extraction, refining and alloying
process is an environmental issue. Because if they are not properly handled, it results to be a huge
source of waste. As the growth of industrialization is very fast, the land for land filling of these
slags is reducing all over the world. Also the wastes cause air, land and water pollution. As slags
are produced in large quantity in pyro metallurgical process, the corresponding disposal cost
becomes increasingly higher. It affects the human health as the vegetation on the polluting lands
and the infected water is consumed by humans.

Mostly the toxic elements present in the slag are Arsenic, Lead, Cadmium, Cobalt, Chromium
and Nickel. Under an environmental slag test it is concluded that the smelter slags contain 23.5%
of arsenic. Incinerator residues contain hazardous substances such as heavy water and dioxins.
Recycling of these hazardous substances take a long term safety for future prospects.

3.5 Cases of environmental impact of metallurgy

There are following cases of environmental issue of metallurgical industries

• In 1950, the residents of Mina Mata in japan suffered from many diseases and deaths
because of having contaminated fish which are infected by nearby chemical factory.
• In Mar copper mining disaster at least 2 million tons of tailing were released into a local
river and caused air pollution.

4. Prevention methods
The metallurgical industries are responsible for pollution problems. The problem must be reduced
and it is the responsibility of metallurgists to protect the environment and human health from the
toxicity hazards due to production of high quality metal products. The environment can be
protected by improving the quality of by-products of industry and the utilization of metallurgical
Chemistry Paper 4: Environmental Chemistry
Module 30: Environmental issues of Metallurgy
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slags. An effective way of preventing these problems is to keep the dumps wet at all times.
Today, planting trees and cultivation of shrubs act as windbreaks and prevent air pollution.

4.1 Recycling of metallurgical wastes

The union of European industries has identified the harmful effect of these wastes and taken steps
to protect the human health and environment against these effects. In which they consider to re-
use of waste to conserve natural resources. Recycling is the most efficient option for reducing the
generation of metallurgical wastes. Slag recycling has been successful in a variety of industries,
for example, iron and steel making industries.

As the protection and preservation of the global environment is concern the recycling of slag is
the priority of scientists. The whole process involves the conservation of lands filled by waste
materials into useful products. The metallurgical industry is directing their efforts into
minimizing and processing the slags in order to meet their environmental responsibility.

Sustainable development is the main objective of the European Union since 1997. Sustainable
development strategy emphasizes the interrelation between industrial development and
environmental protection, economic growth and social cohesion. Microorganisms are used to
extract heavy metals from low grade ores. Chemoautotrophic bacteria causes breakdown of ores
of heavy metals. Sanitary measures are adopted in certain industries to prevent entrance of
industrial poisons by mouth. Which includes change of clothing on entering or existing a shift,
careful scrubbing of the hands and face before eating, and a thorough washing and shower at the
end of the work period.

4.2 Improving the technology

Industry is going through new ideas and technologies to improve the working conditions and
pollution to the environment. It gets involved with the community and aware the employees in
order to avoid accidents. Industries are involved in advancement of metallurgical technology by
understanding the cavitation process. The technology to produce resistant alloys results
improvement in the pump designing and extend the variety of demanding applications. This can
be done with the use of stainless alloy which is similar to the work by cobalt base materials

The improved cavitation resistant alloy resists for long time need in the pump industry. The new
material contributes to improve technology and reduces maintenance costs.

5. Indian prospects
India is assumed to become the second largest steel producer in the world by 2015 as the
production of steel is growing by 6.9% over 2008-2012. Government of India is planning to setup
a strong research and development in steel industry. India has one of the largest metallurgical
industries in the world and the credit goes to several iron and steel factories in India.

Chemistry Paper 4: Environmental Chemistry

Module 30: Environmental issues of Metallurgy
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India is known to be the founder of World metallurgical industry. There are various products of
metallurgical industry in India which includes:
• Foundry, casting and forging devices
• Minerals exploration equipment
• Wires tubes and pipes
• Powder and hardware tools
• Refractories and chemicals additives
• Metal working devices
• Safety and rescue equipment

6. Summary

• Metallurgy is a method of extraction of metals from its ores by removal of unwanted

minerals called gangue.
• There are three processes involve in metallurgy i.e. concentration of ores, conversion of
ore into oxides and refining of ores.
• Metallurgy is used in order to change the shapes of metals extracted and to form some
combination of these.
• Metallurgical process has many environmental impacts such as air, water and land
pollution due to generation of huge amount of waste.
• The environment can be protected by improving the quality of by-products of industry
and the utilization of metallurgical slags.
• Environmental protection can be done by recycling of waste products and improving the
technology in metallurgical industries.

Chemistry Paper 4: Environmental Chemistry

Module 30: Environmental issues of Metallurgy