MSE 304A

Principles of Metal Extraction and Refining

Prof. A. K. Singh
Department of Materials Science and Engineering
IIT Kanpur

Module 1
Lecture 1.2
Flowsheets
Flow Sheets or Flow Diagrams
A line diagram
showing successive
sequence of
operations required
to convert ore into
metal
 Unit Operations and Unit Processes
Unit operations: involves physical operations only like Crushing, Grinding,
Screening

Unit Processes: involves chemical reactions

Classification of unit operations and processes:

a. According to phases involved:
- Gas-solid
- Gas-liquid
- Liquid-liquid
- Solid-solid
b. According to equipment:
- Fixed bed, Fluidized bed, Shaft furnace, Rotary kiln, Retort,
Reverberatory furnace, Electric furnace, Cell for fused salt electrolysis,
Cell for aqueous electrolysis
c. According to chemical reactions:
- Oxidation, Reduction, Slag-metal reactions, Chlorination, Electrolytic
reduction, Electrolytic Refining
 Beneficiation/Extraction/Refining

• Mineral Beneficiation of Ore

• Extraction
– Pyrometallurgy
– Electrometallurgy
– Hydrometallurgy
• Metal Refining
– Pyrometallurgy
– Electrometallurgy
Production of Copper
Production of Copper
Production of Aluminum
Production of Aluminum
Production of Iron and Steel
Production of Iron and Steel
Extraction of Metal: Energy Requirement

Nargote, Jahanshahi,
Rankin, JCP, 2007
Extraction of Metal: Energy Requirement

Metal grade* of the ore is very important. Low grade ore will consume more
energy. Additional energy is required for mining and mineral processing to
remove gangue mineral: 0.5% Cu grade ore require 250 MJ/kg of energy 2.0 %
require only 50 MJ/kg.

*Grade: % Metal in Ore Nargote, Jahanshahi, Rankin, JCP, 2007

Environmental issues

Nargote, Jahanshahi, Rankin, JCP, 2007

 Challenges
• Developing New Technologies for Low Grade
Ores, Ocean Bed Deposits etc.
• Developing Environment Friendly
Technologies
– Zero Waste, Low Carbon Footprint, Low Emissions
• Self Reliance in Strategic Sectors
– Rare Earths, Lithium
• Quality High-end Metals and Alloys
– Sensor, Pure Metals, Steel: India vs. Japan
• Manpower