Non Ferrous Extraction Metallurgy

(19Y502 NFEM)
2021-22
 (Assignment)
Availability of raw materials in India
Metals- minerals in the form of table (with composition)
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 Predominance area diagram (PAD)
The temperature at which roasting is carried out is
an important factor in determining the nature of
the product obtained. In order to get the desired
product, we can determine the best operating
condition i.e. T and composition of the gas in the
industrial roaster in equilibrium with the M-S-O
system.
The isothermal behaviour of some M-S-O systems
with respect to their relative stabilities can be
represented in PAD. These diagrams indicate , for
a specified temperature, those solids which are in
equilibrium with a gas having specified PO2 and
PSO2. Thus, these diagrams serve to predict the
type of solid present that would be in equilibrium
with a roaster gas of a known composition.
PAD of M-S-O system
NiS + 1.5 O2 = NiO + SO2
K1 = Pso2 /P o2 3/2

Ni3S2 +7/2 O2 = 3NiO +2 SO2

Superimposed Co-S-O and Cu-S-O systems
 Smelting
mineral + gangue + reducing agent +flux = metal + slag + gas; -
reduction smelting.
Characteristics of smelting operation:
1. Materials to be smelted are charged in the solid state.
2. the products are in liquid state, some solid may escape
along with gas.
3. The heat required for smelting is usually supplied by
external sources.

mineral + gangue + flux = matte + slag + gas ; - matte

smelting
Reduction smelting is usually carried out in blast
furnace or reverberatory furnace or flash smelter
or electric furnace.
Reducing agents – C, H2, M
Fluxes:
Acidic –silica
Basic – lime
Cover – sodium carbonate, potassium carbonate
Oxidising flux- Na2O2, NaNO, KNO3
Reducing flux-NaCN
Neutral – CaF2, Na2SO4
 Slag
Slag is to collect the unreduced gangue and
impurities. Slag must be a separate layer.
The difference between the slag and metal must
be high.
The slag must be fluid (low viscosity)
High viscosity- leads to metal entrapment
The composition of the slag must be such that
the activities of impurities are low in slag.
 Converting

Smelting is done in reverberatoty furnace.

Matte contains CuO, Cu2S, FeO + other impurities.
Converting is done in side blown converter to
remove Fe, S & other impurities from matte.
Converter capacity 100- 200 tons.
Dia 4m, length 9m, lined with chrome- magnesite
bricks 40cm thick.
Tuyeres 40 No. each 5cm dia.
Air + O2 mixture (O2 -32Vol%) is injected.
Product: blister copper + slag
Converter
 Stages in converting
1. Slagging stage: (need to add SiO2)
FeS+3O2= FeO+ 2SO2
2FeO + SiO2 =2FeO.SiO2 (Fayalite)
Slag is skimmmed off by tilting the converter.
FeS - FeO is an exothermic reaction.
Sometimes extra heat will be generated & Cu
scrap can be added to melt.
Blister formation stage:
Slag is removed . Cu2S is called as white metal
Cu2S + 3O2 = Cu2O +2 SO2
Cu2S + 2 Cu2O = 6Cu + SO2
Overall reaction:
3Cu2S + 3O2 = 6 Cu + 3 SO2
Cu getting converted into Cu2O should be
avoided.
As,Bi,Sb (impurities) + precious metal that get
into Cu shall be removed by subsequent
electrolytic refining.
Ellingham diagram
 Reduction smelting using Carbon

MO + C = M + CO
2MO + C = 2M + CO2
CO2 + C = 2CO
MO + CO = M + CO2
Metals extracted: Fe, Zn, Cr, Mn from oxides
• MO + H2 = H2O + M
• W, Mo

• Metal as reducer
• M1O + M2 = M1 + M2O
Fe2O3 +Al = Al2O3 + 2Fe
2/3 Al2O3 + 2Ca = 2CaO + 4/3 Al
Thank you