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  • Pyrometallurgy Lecture 1. Introduction and Roasting Thermodynamics

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    Nhut Nguyen
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    This document provides details about a course on pyrometallurgy taught by Dr. Ray Newell. The course involves weekly lectures and tutorials, assignments, and a final assessment. The syllabus covers topics such as thermodynamics, unit processes like roasting and smelting, and the production of metals like copper, nickel, and aluminum. Roasting is used to convert sulphides to oxides or sulphates and involves heterogeneous reactions controlled by diffusion through product layers.

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    Pyrometallurgy lecture 1. Introduction and roasting thermodynamics

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    Pyrometallurgy lecture 1. Introduction and roasting thermodynamics

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    This document provides details about a course on pyrometallurgy taught by Dr. Ray Newell. The course involves weekly lectures and tutorials, assignments, and a final assessment. The syllabus covers topics such as thermodynamics, unit processes like roasting and smelting, and the production of metals like copper, nickel, and aluminum. Roasting is used to convert sulphides to oxides or sulphates and involves heterogeneous reactions controlled by diffusion through product layers.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as ppt, pdf, or txt
    680 views22 pages

    Pyrometallurgy Lecture 1. Introduction and Roasting Thermodynamics

    Uploaded by

    Nhut Nguyen
    This document provides details about a course on pyrometallurgy taught by Dr. Ray Newell. The course involves weekly lectures and tutorials, assignments, and a final assessment. The syllabus covers topics such as thermodynamics, unit processes like roasting and smelting, and the production of metals like copper, nickel, and aluminum. Roasting is used to convert sulphides to oxides or sulphates and involves heterogeneous reactions controlled by diffusion through product layers.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as ppt, pdf, or txt
    of 22

    Pyrometallurgy

    Dr Ray Newell
    Email: [email protected]
    Phone: 0417821509

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Course Details
    • Lectures: 2hr/week

    • Tutorials: 2hr/week

    • Assignments: 6

    • Assessment: Assignments 35%


    Final assessment 65%
    Ian Wark Research Institute
    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Syllabus
    • Thermodynamic background
    • Pyrometallurgical unit processes
    • Physical chemistry of pyrometallurgical
    processes
    • Transport phenomena in pyrometallurgy
    • Smelting and refining of selected metals
    and alloys

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Basic Flowsheet
    Run of Mine Ore

    Mineral Processing (physical)

    Metal Extraction(chemical)

    Refining / Alloying

    Marketable Shapes

    Useful Product

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Metal Extraction Methods
    • Requires input of energy
    • Need to break chemical bonds between
    metal and anions
    • High Temperature (Pyrometallurgy)
    • Solvents (Hydrometallurgy)
    • Electricity (Electrometallurgy)

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Unit Processes
    • Agglomeration
    • Roasting
    • Chlorination
    • Smelting
    • Refining (fire refining and electrorefining)

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Metals produced pyrometallurgically
    • Iron and steel
    • Copper
    • Nickel
    • Lead
    • Zinc
    • Aluminium
    • Titanium
    • Other minor metals
    • Various byproducts (gold, silver, PGMs etc)
    Ian Wark Research Institute
    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Roasting
    Aims of Roasting
    • To convert a sulphide to an oxide as a
    preliminary to a metal extraction process
    • To convert a sulphide to a water-soluble
    sulphate
    • To convert an oxide to a more easily
    reduced chloride

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Thermodynamics of Roasting
    The Phase Rule
    F=C–p+T+P
    F is the number of degrees of freedom
    C is the number of components
    p is the number of phases
    T is temperature
    P is pressure

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Predominance Area Diagrams
    • Developed by Kellog to show changes
    during sulphide roasting
    • At constant P and C = 3 the maximum
    value of F is 3
    • Needs a three dimensional plot
    • At constant T this reduces to 2 so have a
    two dimensional plot

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Predominance Area Diagrams
    • Axes show partial pressures of oxygen
    PO2 and sulphur PSO2 species in the
    equilibrium gas phases
    • Lines show equilibrium between solid
    species

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Construction of Predominance Area Diagram
    Consider hypothetical metal M which
    can form MO, MS and MSO4
    M + SO2 = MS + O2 (1)
    2M + O2 = 2MO (2)
    2MS + 3O2 = 2MO + 2SO2 (3)
    2MO + 2SO2 + O2 = 2MSO4 (4)
    MS + 2O2 = MSO4 (5)
    S2 + 2O2 = 2SO2 (6)
    2SO2 + O2 = 2SO3 (7)

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Construction of Predominance Area Diagram

    • For these reactions and for all condensed


    phases in their standard states (activity =
    1) we can write expressions for equilibrium
    K1 = (aMS*PO2)/(aM*PSO2)
    Log PO2– log PSO2 = log K1

    K2 = 1/PO2
    Log PO2 = -log K2
    Ian Wark Research Institute
    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Construction of Predominance Area Diagram

    Similarly
    2log PSO2 – 3log PO2 = log K3
    2log PSO2 + log PO2 = -log K4
    2log PO2 = -log K5
    2log PSO2 – 2log PO2 –log S2 = log K6
    2log PSO2 = log PO2 –log PSO3 = log K6

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Construction of Predominance Area Diagram

    • Values of K are determined from the


    standard free energy change ΔGoT for the
    reaction at the selected temperature
    • ΔGoT = -RT lnK
    • ΔGoT = ΣΔHoT - T ΣΔSoT
    • Can also calculate ΔGoT at the required
    temperature from the relationship
    • ΔGoT = A + BT logT + CT

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Ian Wark Research Institute
    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Effect of Temperature
    • Keep PSO2 constant and plot PO2 as a function of 1/T

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Effect of Temperature
    • Two possible roasting paths
    • Roasting from sulphide to oxide with an
    increase in temperature then temperature
    drops and sulphate forms (a)
    • Sulphate forms at low temperature and
    then decomposes to oxide at higher
    temperature (b)

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Effect of Temperature
    • At high temperatures can go directly from
    sulphide to metal
    • Temperature depends on the metal
    • For Cu, Pb, Ag, less than 1000oC so direct
    smelting is possible
    • For Zn, Ni, Fe much higher so direct
    smelting not feasible

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Roasting is a heterogeneous
    reaction

    A D
    Gas

    Solid C

    Solid B

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    Reaction Mechanism
    1. Supply of reactant in the direction of fluid flow
    2. Diffusion of reactant to the interface
    3. Interface reactions (adsorption of reactants,
    chemical reaction, desorption of products)
    4. Diffusion of products from the interface
    5. Removal of products in the direction of fluid
    flow

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces
    For Sulphide Roasting
    • Oxide layer forms on the surface of the
    sulphide
    • Layer is relatively dense and rate is
    usually controlled by diffusion through this
    layer
    • Long time needed to oxidise last traces of
    sulphide
    • Reactions occur quickly for very small
    particles

    Ian Wark Research Institute


    Australian Research Council Special Research Centre
    For Particle and Material Interfaces

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