METALLUR4y

conver iinq ore to

Prcess et PUre mete
Meta llwgy

Types & metallurgy

Au, A
y d r o meiallurY
neta \lumy Fe,
yro Mo A.
LElecro metallurgy-

STEPS INVOLVED IN METALLURGY

Concen 4ration Ore re dres ben e lication
Step 1
Chemi ca me thod
Physical method

Maqnetic Sep oticn Lleechig

Pgravity Seporation
froat ietetion proess

MAGNETnC SEPAPA TIoN

is aderted me ore anqve2

Cimpurties) re moqnetic atae.

re

mognet

maqnethe hon moq netic

Part art

exawple i n themetallury Iron

maane Rc
the o e MAGNETTE C Fe
h e a OG im Purities on wcqveT¢

he me tallurgy Tin tic

o the e TIN STONN E CSn is

1 9n e h r

mpurty oLEPAMITE ( e wo) is ma

chroma e (eCr ) maqneti c

mpurities nen maq n e h c

PyRoLUITE CMnO) maqne tic impuri ties

mog
 PAVITY SEPARATio
t used Concentra tion
OXIDE ores and CAR BAA TE bres
since
e ave iaher impuri ties
Can ee carned a y
unlna ater

impri HeS

ashed any y
water

Ore
i g h t e r impur hes
HYDRAULIC NASH ING

t e r
- h i e r ere
sent n

4throua
hian preSUre

FLOATA TON PROCESSs

FRCA TH Sulphide
Genera y applia weta louby
impuri i g
Principle: derere
ater
o i l resp
and ore
wetec
Dater.
ore wetad

impur
brnsk ne slu tion,
to
air

roath i n e oil/Eualy
cs ptus si\/ ampor

cresols/aniiee

frcathers roath stablisers

ore in
puriies
role. orina ore cllector
xan t h a t e
ter atoch to rot SodiUm

etny
S
CHO Na" s=g sNa

(iee achc n+)

Exawpe PS GGalena
smilar moelty eets dsorked
Note nemicaly
hemically E

( O
PLS-Et--
yeopne aC d rephiic
E
E
rel)
xanthate qes
he supnur part etmy
odsored Cphysisor lhed) OTt PSand orinas it
since E S

Acti vators a s octhivotes towards attochina with reh

Pepres sanhs deoctivahces ousards ataching oit t t

Ewnmle PLSZS+feSz (Fess)

NaCN Cdepressani
ZnSt NacN No LZ CCN) ] +
Na, S

we nt only Pi rot
Fes nas low attini y o
etnyxontheate
Nou PS Arcth is removed.

GaSa Na(z(c)3 W JENR Dalcaen),3

(acivatr ) Z2
Na s ZS

we can s e rotn e a tation Prcess er Zn>

LEACHING
Ore Leoch ng mPurn tirs meta par*
aet
Cisolule ) seluble fo rm)

f:lterati ow
Exmpe Bauxite.
A
Pas boauxi te
wnte banxite
Fe m pu h t y

mpury rpex Rees

Ped banxite Can be veer
Bayers Puriied usiw Alumi viv

Lnchin ye Naolt ocess

c
 NaoH
NaA e , ) + impurities
Bau xite

seluble here only

achin t

ter

resy re ACoH) oY P s c o
seedin aent*)
H
rems e
AR(OH)
A rom

e o m to
ove it

t o rw a r d .

An.
vsetor A ha,
Leachin
Silver Glance -Aa,
Avnentite or)
bxaweL Na S
NaAq2
(selude ) ir
laching9
gem
Carried
Ow Nas°4
to oxidise NaS
a
Presence eomwd
to moVE
CYANIDE
CyANIDE
MAC-ARTHUP-
N-KeTHUP-
FoPES T
FoREST

PRoCESS SyNTHESIS

CYANIDATON

broth Ag Au

t NaCN
state
Au in
natve

is
Gold
ore

hove om w
rauired

OXyae
A uAu
A
STEP 2: Conversion & the Concenrated ore
im
its oride form
ce
rauchion oxide to Pmetal
easier
is

to Convert
t oxide
form
e want

POAS TNG
CALLINATiON
for ores
o ores, C
oes
for
r e i s heated
below Mf
ove is hmied
prese n e air
o r im
absee e st
MS O2 MO So
lon quan hty sair
ai)
As,ST VapovS
A - A SL-so
S-soT, P O.T
e remMoved
vola ile impurities
calcina tion)
exawnpe As S b - T v a p o u r s L
As So,o Croasting)
mater aet removed
voldnle oraaiC
aet removed
ermoistue
Carnied Ont in
calcination roastinaa
PEVEPB EPATOy UeDACE
MO is asier han MS
reducina
PAPTIAL PoASTINg
tor C Po rom neir enlpwde ores
eun
Ame sO 2 Pduced in tastivs
suseduse for wanutc
STEP 3 SNELTING4 PewCTION OF OPE
Smelti S a ormation

Caben S Ued aAS redwcinaA nent in Smetinq g h t e r

slag O
m a l k a

m et a

(3 ge)
Acidic in Basic in awre
oture
Basiclm)
CAcic )
Exomple
Exape Iren
U Sed n
SO2 Cen SiO
aidic
bricks,cemen
imPurAY
Calum iicate
Cao P Co 2
aci d i Sa
B o s c

mp Calivw hosp hate

THoMAS SLAG
mel
CoPP use as eriliser

Fe SiO3
FeO
aLidic

Gron si icate )
a s e i m p u n t y

Preteats he nolten metal rom

Over it
a layer
nrdher oxidation tormin
and hus eu Hina ot
iSamter)
(ince tmosphere.
ith
C o t a c 4

i n e a c h o n
ot many

and e
Carecn is cmeAP Sn
i ke
-

Fe, Zn, P C
etas A
Alumini um mintum E
E
used for edwi e K +h metals s e
alkalinhe
orms Carbides Ingted.
A l a l im e t a l s
reuired
hiaer
a t h e

&t -e)
ELLINGHAM DIAGPAM
As ve S
M Ls
M (s) he
free energy Chanae

me Consum ing
de
AGhere Tt its
exí
M
o n v e r s j o n

Conga n t
mde oye A iSs almost

we
will
ormatien
T A

T, AG for
AH at
+Ve
A,o
2g1°2
t o r As,
is -ve

T deide appopihe reuan

UseE m a h a m iaqram wel to
ongent
 HERMAL PeuCTION suicien t exract
it Oxde

AgH tom
2hg °2
Ag
H 2
NorE Aa Ag

Geneally MCO> Mo co2

A3 hg are hermaly unstabee
lon

CAu) Ploqtinum ( Pt)

S net form
Gold
Stade Ox i d e s

PE
AM
Au H

Mg
-Al0
ChanS are
alo rup
- 1200 acco m n - e d ey
e hase

T2 Charges duri has

+rans ormont en
AR Mg Ma AR
LMgs) Mgc)

at T C-iood) -2o0
is fsiL
a t Ta LG = oo - C-D0 +200 Tx is not fease

The metalss
whe are ower in linaham
m e i al s
d ram dan red uue +ho xides - 4he
a lumIMo h e r m i t e educhon
AOT Fe
s hishly exethermic, e Lill
tis
'.iLis wediv
s in e

meHen stote
use
iiM
M e g n e s dm
e
rioen esily Coteh
M e yw e s i u m
Yiven
Us t iante
stert h e rxns
he
Pve S t e r t

re
ix+

hiq tinty or7yen

Alumin i Um

orr
t+o
eduction
eduction

hermi
xn is us
A u m i n o

Oxides
Mn, Te
is more esnomally
arbon
sing
R e d u c h on

ensible

Al2©3 + r
CrO+ A CARBo
US ING
keDUCTIONS
Co
O2 A S = + v e
A S : * v e

20 g)
2-cOg
(e)
22C)
*
O g) A S -ve

2CD
2c°cg) 29
AG - sH-TAS

c o

T o°e

T oc Co
to
Coereion s
(unverSion Co to CO2 le
more ea sib
moe easie
iS actual educi
actual redue
CO
Ooent
OTHER TYPESf PEDyCTIo
Electroly tic eduction

all s lock elemen owrs eell-A

He roult prore
aluminiom Cl
Carloen redwtion
Zn
f e S n , re, Zn

Sel educhic
P H

Hyo metallurgy
A u , Ag, PE

T h e r m a l reduCHon

Ha,
Hydroa en Yedwetion

Mo, W, 3,In
MoO3 H redHot Mo H,O
fed Hot

ed It
H6
e He In 40
PeMaonesiuw eduction:
oosoES Td Mg Tt+Ma
TEP 4 REANINNG OF METAL
e ACTioNAL Deri uATioN
have low BP MP
Zn, C
blecE metals' neta lie bond strenq
partipaton nSe
decide y
e l e c t i onsS
w peied

Con.
Zn,Cà, t i 9 - ( K - ) J

invol v e i v me IC
bnly nS
me
tallicbond stran h
ondin ilo
MP, AP iSos

EFINING ef Zn
q2C
Z
tie s C
impuri
Asseciaded
S 0 o C

443c

Pesidue
ed
Zn
Recid he oo V a o r s
Fe,Pe
Vapeur»T
Z, Fe,Pb
C

Peinins
Phoce
VapCur PeocesS
N
MoNDDs S o - 4 0 ) c

T
m P u r i i e s

T [NE(Co)]
mpure + LO

(23 D-2s )
cot
Pure

NECC RoCESS 3JoDINC PHAC

Va ARrEL
eZ, T,} mPur tie <s
T: I
mPurL a niger
T
Tt I ,T
 AMALGAMAToN
Au, As

-
imPure
metal
CA+ metal) layer
Cmolten)
fFer
=
Mehal + Ha J decant)
Amalgam
impuries
Hs
M e tal
-

dieti\la tiov
Mel H

PouNG
Ca, S
Contain i s own
melal
hen he impure
imput ity
Oxide aS
As 3 ee we poles
S°2
generates nydocar bshs

molten eucn AGEMt

meure men

redwe meta eide

t oexpel vsatile

impuriifes as such metal

O x i d .

OY
sn
e As
s unaloe do
the Yhetal
reduehoh, all o
dun stee hott rednctiou
S C o m p l e l e d

r e d u e to metal
Prif
ica How
Step
Liovt TOn
Sn,Pb Bi.

m.P me ie 4m.P impur ty on

s haled
mpure me
slo Py urnar e
mpu ri molten metas
CPue)
heat
 ZoeE PeFiN IN
Si, , Ga Cultra pure)
leete in
m puri Hes dissalve
Prin naple
molte melt)
sluble in
r e

impurities

mputi H
mol ten

meta

hte

CuPELLAHON as impuri
Au, A Cowtaini
impity attinit
more
has

An 9
Pricip e hav
wdhstand

hot a i Cnv
4hat
C u p e l v e s e l

temP
iq
m P u r e

m s e ferm
a k e m

ron
wrouqht

PuDDLING
( a 8 7.)
YON
ure
(as 7)
Pure
coa, So2 Pa1
Co

SO2

Cmo+en)
SiO
Fe23 SioQ fe
Si+
My e
live it fes Mnt Fe,2
SiO. Mn SiO3
Mpwi - c,s,P, si
MnO+
Lslag
 REFINING
ELECTROLY TIC
Universa method
m e t a - Anode
imPre
Cnthede

Pure metal
uitabe, sper to metal
elecholy t e

Catho

a nade
Pure M

mPure
M

Anoe M

mud
Gmpurtty)
anod e: M- e

Cothed e , M

CuAg, , A A ,ZnS, N
used for:
ORES
O x D E O R E S

CorunduM- A , o

e
Bauxite
AL32,o A OCo4)
CoBauxite is
3-2 NeTE
Zinciie
ZnO
a s useV
Hydroxide
Cupriie ()Puoy lepper as oxide ore.
Chvome- fec'4
luie
ro
Mu -

Py
Cssiteite/Aimston S n O
(Haematite - Fe°z

Mname tite.
Feu
Limunite Fe2 3H2
Kaolinite
-
[A si,°s
Si°5 orm &cy
SPHIDE ORES

or) Chalcopy rite

-
feS2
rite 2
2 22
CoPeY
Blende
-

ZnSsalente .S*FesFe
Zinc
a l e n a

HgS
C n n a a r .

Cfocls Gold)
-

FS
Ivrew PYr1te
Aaenhie - A

CAREONATE OPESS
Calamine -ZnCO
C e r r y s i t e -

MaO3.Cal°z
D o l o m i t e -

Yon
Feco
Sdente or) Seehahc
nCO CuOH

Maladite are - 2 CnlD3. CuCoH2

Azurite ve

nesite - Mg
Me

HALIDE ORES
Horn silver -Aog

Sylvine
k u .M j .6H
Carnallite
-

CaF2
FluorspaY
Cryolite -Na A
NITRATEe ORes Cmains

ile Scit Petre NoNO

Indian Slt petre NO
Bega
OF INC
XTPACTION
Zn CD
Zns
Zinc Blende
Calaie
Concen r a tio
Concent va tisn y
b y ravity Searatio froth loata titn
Conce trate d sre
Concemttaie e

Roogh
caleinatien

Zno9
ZnC Znotco, ZnS2

Con tains Si2 a impurity

Smeli
m e Stone
* Yeducia caen
ne a well a s

COSO2
CaD
CaOt S:o2 Casid3

Zno Zn tCO
molten

Zn Speter

Puri fi cation
fracional diailla dion
O z [Fe, b l
c Z asc1 7,e,P
(420'c) (16)
Electroly t reinig
mpure Zn Pure Zn
Avode Catho de

Electro
ly e : Zso, /4* callak
Zn+C co
cok, 161S zntco mea) is dsHl }} cl
y vapi chillim
 PACTIO N OF TIN
SnOz +
St FeS iica 1 silicates
inst e / eraite tWof ramite CFe o , )
Ti

concen raHon y vavity epara tho

Cone trate. ore
removes slicaks)
SnOz
CuStFeStSiO,t fewO4
2o asti Controlled Ynan n e r
Conver 6 m to Solu be S
Sieiento s adde

P e s i d u p e
Fiterale

Fe O4 Sio2 Fesu CuS°4

tis
maa netic ee ara

Fe O 4
SnO2 Si02 |
Black tin

S melt\mg Presence

stC Calo

CaD (O2
SnOC Sn C O Calo
CadS - CLpCaiO3
Ce, Cu xides Slag
Puri picaion .

O Liqua tion

Po ling

Elatro ly tic reining hexa

(apelefluorosilic ad)
SnSo HSD, sit
Elecroly e
ExTRACTON OF GOLD
oRE
A u e fEPPoS
Feom
Con e n t Y a t i o
removegd
are
puriIS
siucate im
Concem trate d ere

yanide rocess
Mac- Arthur- forest
CyANADATION PPOCESS

NacN CLeachim cess)

addn
(oyaa is vequi
Na tAu (C) tomore aom twa)
N aCN
Au +

esidue
PiHerate
wrther reinin
Amoaao m tion

Z e e c t o l y tic
N 2 ) An eining
sdude) Eecrsy te: Aud3.
Paiicatin Cop)
Z, P, , A
A
conc. t e r e

Reside
Hemie
Znsou
Au,Pu, *
Capelat

Au, Cu, AS Pof

wit Bora x
shely heaied
Ho s ded (BoTax leed
est)
Pesidue fiHerate
An, A s Cul . , (Ee)

shreay taed i presee o

Conc SoL

Au ASo4
LXTRAC
TION OF SIL VER
FReM AR ENTITE No rothn tleataton
eTe
S rauied.
A 2 ith DacN
leachinq direct leaching
Presence

A S Na C Ag Ce), ] Nas
CN
CN A
t
N

Pesidue Cshits td)

Na A C ) ] mpuri ies

Slu ble

(zn,7 A
S o l u b e

Puriscaion

Amalaama tion

Electroly tic relsining

AOHN
Eecheyte:
FROM ARGENTIFEPRoUS 2oCk
ROCK
is a s s c i a te
nt it
naive state
Silver exis Cike P
impurities

ith

slid
|velt
Ag 4Plo
Cmolten ferm)
TAREL Z
Zn Vapou rS
PRoLESS Sirred
distilla ien
P
L-
Aq-2Zn 20°C
A +Some Pb

Cupellatio

PLD
P b hacue ? A
Pun fica tion

(DAmal qama fion

tining
E l e c t r o lytic e
Electrolyt e : Agno/tSob,
 EXTRACTION OF LEAD Credctisn i puritiesan
PLS
C+ ZnS )
alene ) ore

Concen +a ticn
s e l f redve Ho
P a r tial rovas Ha)
by roth f\«katah on

aCN depesand

No CN Zn Na, LZn (cn) 3

As vet ge aHache

wit tre
Concentrated Oe
( costi with
me ssne

PLSto, PLO tSo1

PLSOLCHle )
Ls PO Psio,( slag)\ Ahis ran needs t
avo ided . so w e ad
CaO Si0 Casid (slan)
Calo
Cat Ca0+ 2.
CaD is mere asie han Ao
P , PlSOu Sag
Casioa
Smel tina with Ct Fe o

PLO C P* co

Feb Si° FeSio ( sag)

e Poso 2 C IPb t 2C0 *So,

Puiicatioy
Liqvaticn
Elechroly tic ve tinina - BETT's Peocess

Elecho lyte : F +PbSiF

PL
 when
PARTIAL PoASTIN 7SELF PEBDCTIoN
Concev rateed

roastina in limite
Spely OYe

a t e r seme fime, air

suPPY is eute4
avd more re iS aded
Po 2
P T 2 PhoSoCHe)
P tPLO biso
P T PLSO Plot

xTPACTioNS
OF CPER

Cu
C Cuol2 :
Cu SeFe,
() Malachite green
Azurite
olue 2Cu C6z.Cu loH),

chal coPy i e )

) Cule S22 cppe

1otaHov Process

o r oxyge n
Concen tra ted
r e t e r
ffini y
Roas ha iren y Hle Cnzis ormed

an Copper reenc with rmea

r e n Fe S Usill

e the
Fe6&Cu2s
to ve

Cu ¬eS feCu, S
C +2
Cr S i o imp
Sio,
FsFe
Fes,Feor
CS,2,
e
preeewe
Smel H hg
ectS ad u e enly
coke
her e

FeO+ SiO2 Fe Sio (sag)

FeSiO3
Cu
Fes
extern l
Copperwmate
air
wit Si2
added
1
Heated im Presence
CT)
?
Feest o F e O+S6,
FeSio (slag )
Feoi O2
C ,S
Cmel ten)
 BessEMERI SATION
CScoPper
ma He takes lace isa
shou
vid *Fes Beesee Convertyr
e le air (T)
Ims Heted presere
i t SiO adeded exter nay

e St Fe S,T
FeOtSiu, FeSiO (sag) enlae
n Cmel ten)
heate at further hioner copPe
wa He

tempC) T.)
se YeducHdn csccurS BessemEr converkar
CuS lined wit
Cu,O CuS
Cliste r cspper)
Pame indicaBeds Pcsence

een
he emp ist to T
reenlames stop Com ing,
One

Parication couper

Pollig
Eleckoly tic
elec te y te: CuSD ,so

OTes

CuFes Chalcopyrite
CuS coper la nelchaLocite
Careonate-Vmalachite reen
CuCCn (oH), onsic CoPper
- 2 u r i t e ldve
2 CuLOz Calo#)
C -Cuprit e Cruby red cslour)

Cus FeSu oornie/ pencetk ore ( in idescet)

9 a d ea s
Corer
Coer1 extYacied by HyDRo META LLUPGY Scew lou
eched out i ocid ac te i a The

Selu tion
cowtoivn9 C is trealed t scrap i6n
Ane
re

CnCa 2t
TPA CHON OF JRONN
Haencte - Fe, c

M tite Feu
Sderite Feco fer
h e t use
ron riie Fes Fools qo exttmct ion

sine qva liy

Limen ite

Haenae
G r a v i t y e p a a t i a

donten t r e t e re

hou
net C separa
wmaq

non maaneh

m n e t H C
impriy
s
sutien*
sufticient

roosi t i e ( a l e i n a
tion
ve
C a l i n a h i o n

COse
both
he
wane hke ciaerie
Cose o s ha
in equired
bnt oA iM are
Omd
caina tiON
Feo istvean ermee e o

Fe 4 °2 iron by
Uaste

Letthn eeO o

Fr6t Cemeino w i t SiC

fe
i n the case
hee m a Hte )
Caldned ore
sidente)
he
he ce maqne Fi Ae
ased ore C
me Stone
Coke e
mie wi +h BLAST FuPAE
ein
and

ore coF¥e iechone

Charge
2one(
206
-9 o s )
reduehien
2one 3 o o - I o o 0 c)

sag formaiim
one C 1o60A500°C

H360C)
iso
b u s i o n
n e
Cc m
eaeoy
latera
HotA

SA
mol ter on Cpig ron
Reducton 2one
c 2o0-Esou'c)
te3*
Co> Fe 1
CSc -o ' )
(o
F e o CO
Fe C6co -3 oo't )
Fe T
Fe t Lo

SiqSormation 2one

CabSi CaSiO (slaa)

CoPo, (thevmas e-peset in
very H le
amoun+
usion 2one
M
MnO2 As
As
Po mied t h molen Fe
S

Ca u ) , Si02
AH = Ve snic redues the
emp i (ompir}son
endothermic)

tomousion Zene

Com bstion aon e

C CO2

Puniica ion (4e)

OPudligR ire
Sc Cap iY OM
Pi ir Caste ivon
(37.c)
(4/ Catoen)
wroa îron
Presi or iron
ALLOYS

Brass

Z 36/.
Cu (8 3-1c)7.
B r o n2 e -
Sn (-12).

CSo7
Germah
Zn 3o7.
Sver

Ni 2o/.

A 1S7,
P ur a l u m i n

Cu 47.

Ma 0s.
M 0.57

ElechrD)

Z n 4:57.

Cu b.S7

Cr -12-14).
S t i nless
Stee - ( 2-4)'/:
Fe rest
Cu 8 4 .
Gun meial
Zn 3/.
Sn o
Cn 8 6 /
Bell metal- Sn 207

P So
S So.
Solder