Introduction To Metallurgy

INTRODUCTION TO METALLURGY
Metallurgy: Science and technology of extracting metals

from their ores and of compounding alloys.
BRANCHES OF METALLURGY
•Physical Metallurgy (Physical Properties of Metals) studies
metals and metal alloy systems, atomic structure, equilibrium
and phase diagrams, stress etc.
•Mechanical metallurgy (Mechanical Properties of Metals)
deals with stress-obtain relationship, fatigue, mechanism,
elasticity, plasticity, pressure shaping of metals etc.
•Foundry Engineering- moulding and casting of metals and
non-metals into dimensions, shapes and size.
MCE 329, LMU, MECHANICAL DEPT.,
ADEDIRAN A.A
• Heat technology includes heat treatment of metals
to gain physico-chemical properties that cannot be
obtained directly from furnaces.
• Extractive Metallurgy entails production and
processing of various metals; it studies chemical
and thermodynamics principles involved (Chemical
Metallurgy)

ADEDIRAN A.A
CLASSIFICATION OF EXTRACTIVE METALLURGY
It is almost impossible to follow consistently any

pattern of classification, but three major types of
classification could be considered according to:
PHASES INVOLVED
• Gas-Solid Examples; Roasting, Gas reduction. Roasting
of sulphides to form the oxides and sulphur dioxide.
2ZnS(s) + 3O2= 2ZnO + 2SO2 (g)
2FeS2(s) + 5.5O2 = Fe2O3 + 4SO2 (g)
Fe2O3 + CO = Fe3O4 + CO2
Pyrite by product called pyrite sinter

ADEDIRAN A.A
B. Gas-Liquid Example: Bessemer blowing, distillation. The
blowing of air through the molten iron-copper matte with
simultaneous addition of silica in the Bessemer converter.
2Al(s) + AlCl3(g) 3AlCl(g)
C. Liquid – Liquid Example: slag-metals reactions.
Desulphurization of liquid steel by means of a basic slag given
by the reaction.
[S] + (O2-)(Slag) = [O] + (S2-)(Slag)
[S] + (O2-) + C = (S2-) + (CO(g))
[Fe (Mn)S] + (CaO) + C = [Fe(Mn)]+ (CaS)+ CO
Blast furnace Operation

ADEDIRAN A.A
D. Solid–liquid e.g Liquation Leaching and
precipitation separation of iron from tin, keeping
the impure tin at temperature above its melting
point, the compound FeSn2 will separate out as a
solid phase, leaving behind a liquid with less than
0.01% Fe Liquation- the draining of almost pure
liquid at an inclined angle.

ADEDIRAN A.A
Most metals are found in nature in solid inorganic
compounds (minerals) except Au and Pt, Pd, Rh, Ru,
Ir, Os. N.B source of minerals → oxides (O2-),
sulphides (S2-) and carbonates (CO32-). Silicates are
abundant, BUT they are generally difficult to treat
(not economically viable)

ADEDIRAN A.A
ADEDIRAN A.A
What is involved?
• Mining (then crushing and grinding)

• Concentrating the ore → remove the gangue
• e.g. magnetic separation, flotation, amalgamation
• Reducing the concentrate to obtain free metal
• Refining/purifying the metal
• Alloying→ mixing metal with other elements to
modify properties

ADEDIRAN A.A
Pyrometallugy
Use high temperatures to alter the mineral chemically
and reduce it to the free metal. It requires large
amounts of energy and often the source of
atmospheric pollution. Used in concentration,
reduction and refining processes.
Some pyrometallugical processes include; Calcination:→
Heat ore to decompose and eliminate volatile products.
Carbonates are often calcined to drive off CO2 and form
metal oxide e.g.
PbCO3(s) → PbO(s) +CO2 (g)
Δ
Require temps ~400-500oC (1000oC for CaCO3)
Hydrated minerals lose H2O at ~100-300oC
ADEDIRAN A.A
• Roasting: → Thermal treatment causes chemical reaction between ore
and furnace atmosphere.
→ Leads to reduction or oxidation (depending on atm) and may be
accompanied by calcination .e.g. Roasting of sulphides to produce oxides
• 2ZnS(s) + 3O2(g) → 2ZnO(s) + 2SO2 (g) e.g. Sulphides of less active metals
can be roasted to the free metal; HgS(s) + 3O2 (g) → Hg(g) + SO2 (g)
e.g. Free metal also obtained by using reducing atm: PbO(s) + CO(g) → Pb(l) +
CO2 (g)
• Smelting: → Melting process in which material separates into 2 or more
layers in a chemical reaction. → Form molten metal + slag

ADEDIRAN A.A
• Slag forms when basic metal oxide reacts at high temp’s with molten silica
(SiO2) e.g. CaO(l) + SiO2 (l) → CaSiO3(l) Slag = mainly molten silicate minerals
(with aluminates, phosphates, fluorides and other inorganic compounds)
• Refining: → Treatment of crude, relatively impure metal product to improve

purity. → Produce pure metal or mixture of well-defined composition.
• PYROMETALLURGY OF IRON: Source: iron oxide minerals e.g. hematite =

Fe2O3, magnetite = Fe3O4
Reduction of iron oxides → in blast furnace
• Charged at the top with mixture of: iron ore + coke + limestone

ADEDIRAN A.A
Coke = coal heated in absence of air to drive off volatiles; = 85-90% C; Fuel→ produces
heat as it is burned in lower part of furnace Also, source of reducing gases→ CO + H2
Limestone = CaCO3; Source of basic oxide in slag formation; Hot air blown in from
bottom of furnace for combustion of coke.
Reactions in furnace: Combustion of coke: 2C(s) + O2 (g) → 2CO ΔH = -221 kJ ;
Water vapour also reacts with coke:2C(s) + H2O(g) → CO +2H2 ΔH = +131 kJ
Limestone is calcined in upper part of furnace: CaCO3(s) → CaO(s) + CO2;
Iron oxides reduced by CO and H2 in upper part of furnace:
ADEDIRAN A.A
e.g. Fe3O4(s) + 4CO(g) → 3Fe(s) + 4CO2 (g); ΔH = -15 kJ
Fe3O4(s) + 4H2 (g) → 3Fe(s) + 4H2O(g); ΔH = +150 kJ.
Reduction of other elements also occurs in hottest part of furnace where C is the
major reducing agent. Molten iron collects at bottom of furnace with a layer of slag
on top. Tap furnace periodically to remove iron(also drain off slag). Tapped iron is
NOT PURE contains Si, Mn, P, S, C.
Formation of steel:
Remove impurities by oxidation in a converter; use O2 or O2 + Ar as oxidising agent;

C & S expelled as CO and SO2 gases. Si oxidised to SiO2 and adds to slag.
Presence of basic slag NB for P removal: 3CaO(l) + P2O5(l) → Ca3(PO4) 2(l); Monitor
O2 coming off to see when reaction is complete.
ADEDIRAN A.A
Hydrometallurgy
Leaching: Desired metal containing compound is
selectively dissolved. Leaching agents used: H2O or
aqueous soln’s of acid/base/salt→ Often form a
complex ion. e.g. Gold concentrated by the process
of cyanidation; Leaching agent = NaCN soln in
presence of air
4Au(s) + 8CN- (aq) + O2 (g) + H2O(l) → 4Au(CN)2-(aq) +
4OH- (aq) ;Au(CN)2- is then reduced by zinc powder;
2Au(CN)2- + Zn(s) → Zn(CN)22-(aq) + 2Au(s

ADEDIRAN A.A
Electrolysis of molten salt or aqueous solution.
• e.g. Na, Mg, Al; H2O more easily reduced than metal ion.
Electrorefining of Copper to obtain pure Cu
Anodes = large slabs of crude Cu; Cathodes = thin sheets of pure
Cu; Electrolyte = acid soln of CuSO4; Apply voltage→get
oxidation of Cu at anode and reduction of Cu2+ at cathode;
Oxid. & reduct. more readily than that for H2O.
Impurities in anode includes: Zn, Ni, As, Se, Te, precious metals
incl. Au & Ag
Metallic impurities that are more active than Cu are also
readily oxidised at the anode, but do not plate at the cathode
because their reduction potentials are more negative than
that for Cu2+. Less active metals are not oxidised at the anode
→ collect as sludge below the anode
ADEDIRAN A.A
ADEDIRAN A.A

Introduction To Metallurgy

Uploaded by

Copyright:

Available Formats

Introduction To Metallurgy

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Introduction To Metallurgy

Uploaded by

Copyright:

Available Formats

INTRODUCTION TO METALLURGY

Metallurgy: Science and technology of extracting metals

MCE 329, LMU, MECHANICAL DEPT.,

It is almost impossible to follow consistently any

MCE 329, LMU, MECHANICAL DEPT.,

MCE 329, LMU, MECHANICAL DEPT.,

MCE 329, LMU, MECHANICAL DEPT.,

MCE 329, LMU, MECHANICAL DEPT.,

• Mining (then crushing and grinding)

MCE 329, LMU, MECHANICAL DEPT.,

→ Leads to reduction or oxidation (depending on atm) and may be

accompanied by calcination .e.g. Roasting of sulphides to produce oxides

• Smelting: → Melting process in which material separates into 2 or more

layers in a chemical reaction. → Form molten metal + slag

MCE 329, LMU, MECHANICAL DEPT.,

• Refining: → Treatment of crude, relatively impure metal product to improve

• PYROMETALLURGY OF IRON: Source: iron oxide minerals e.g. hematite =

Reduction of iron oxides → in blast furnace

MCE 329, LMU, MECHANICAL DEPT.,

Fe3O4(s) + 4H2 (g) → 3Fe(s) + 4H2O(g); ΔH = +150 kJ.

Remove impurities by oxidation in a converter; use O2 or O2 + Ar as oxidising agent;

MCE 329, LMU, MECHANICAL DEPT.,

You might also like