An ore is any naturally-occurring source of a metal that you can
economically extract the metal from. Aluminium, for example, is the most common metal in the Earth's crust, occurring in all sorts of minerals. However, it isn't economically worthwhile to extract it from most of these minerals. Instead, the usual ore of aluminium is bauxite - which contains from 50 - 70% of aluminium oxide
Concentrating the ore This simply means getting rid of as much of the unwanted rocky material as possible before the ore is converted into the metal. In some cases this is done chemically. For example, pure aluminium oxide is obtained from bauxite by a process involving a reaction with sodium hydroxide solution. This is described in detail on the aluminium page in this section. Some copper ores can be converted into copper(II) sulphate solution by leaving the crushed ore in contact with dilute sulphuric acid for a long time. Copper can then be extracted from the copper(II) sulphate solution. But, in many cases, it is possible to separate the metal compound from unwanted rocky material by physical means. A common example of this involves froth flotation. Froth flotation The ore is first crushed and then treated with something which will bind to the particles of the metal compound that you want and make those particles hydrophobic. "Hydrophobic" literally means "water fearing". In concentrating copper ores, for example, pine oil is often used. The pine oil binds to the copper compounds, but not to the unwanted rocky material. The treated ore is then put in a large bath of water containing a foaming agent (a soap or detergent of some kind), and air is blown through the mixture to make a lot of bubbles. Because they are water-repellent, the coated particles of the metal compound tend to be picked up by the air bubbles, float to the top of the bath, and are allowed to flow out over the sides.
The rest of the rocky material stays in the bath.
Reducing the metal compound to the metal Why is this reduction? At its simplest, where you are starting from metal oxides, the ore is being reduced because oxygen is being removed.
However, if you are starting with a sulphide ore, for example, that's not a lot of help! It is much more helpful to use the definition of reduction in terms of addition of electrons. To a reasonable approximation, you can think of these ores as containing positive metal ions. To convert them to the metal, you need to add electrons - reduction.
Choosing a method of reduction There are various economic factors you need to think about in choosing a method of reduction for a particular ore. These are all covered in detail on other pages in this section under the extractions of particular metals. What follows is a quick summary.
You need to consider: the cost of the reducing agent; energy costs; the desired purity of the metal. There may be various environmental considerations as well - some of which will have economic costs.
Carbon reduction Carbon (as coke or charcoal) is cheap. It not only acts as a reducing agent, but it also acts as the fuel to provide heat for the process. However, in some cases (for example with aluminium) the temperature needed for carbon reduction is too high to be economic - so a different method has to be used. Carbon may also be left in the metal as an impurity. Sometimes this can be removed afterwards (for example, in the extraction of iron); sometimes it can't (for example in producing titanium), and a different method would have to be used in cases like this.
IRON AND STEEL
This page looks at the use of the Blast Furnace in the extraction of iron from iron ore, and the conversion of the raw iron from the furnace into various kinds of steel.
Extracting iron from iron ore using a Blast Furnace Introduction The common ores of iron are both iron oxides, and these can be reduced to iron by heating them with carbon in the form of coke. Coke is produced by heating coal in the absence of air.
Coke is cheap and provides both the reducing agent for the reaction and also the heat source - as you will see below. Iron ores The most commonly used iron ores are haematite (US: hematite), Fe 2 O 3 , and magnetite, Fe 3 O 4 . The Blast Furnace
The heat source The air blown into the bottom of the furnace is heated using the hot waste gases from the top. Heat energy is valuable, and it is important not to waste any. The coke (essentially impure carbon) burns in the blast of hot air to form carbon dioxide - a strongly exothermic reaction. This reaction is the main source of heat in the furnace.
The reduction of the ore
At the high temperature at the bottom of the furnace, carbon dioxide reacts with carbon to produce carbon monoxide.
It is the carbon monoxide which is the main reducing agent in the furnace.
In the hotter parts of the furnace, the carbon itself also acts as a reducing agent. Notice that at these temperatures, the other product of the reaction is carbon monoxide, not carbon dioxide.
The temperature of the furnace is hot enough to melt the iron which trickles down to the bottom where it can be tapped off.
The function of the limestone Iron ore isn't pure iron oxide - it also contains an assortment of rocky material. This wouldn't melt at the temperature of the furnace, and would eventually clog it up. The limestone is added to convert this into slag which melts and runs to the bottom. The heat of the furnace decomposes the limestone to give calcium oxide.
This is an endothermic reaction, absorbing heat from the furnace. It is therefore important not to add too much limestone because it would otherwise cool the furnace. Calcium oxide is a basic oxide and reacts with acidic oxides such as silicon dioxide present in the rock. Calcium oxide reacts with silicon dioxide to give calcium silicate.
The calcium silicate melts and runs down through the furnace to form a layer on top of the molten iron. It can be tapped off from time to time as slag.
Slag is used in road making and as "slag cement" - a final ground slag which can be used in cement, often mixed with Portland cement.
Cast iron The molten iron from the bottom of the furnace can be used ascast iron. Cast iron is very runny when it is molten and doesn't shrink much when it solidifies. It is therefore ideal for making castings - hence its name. However, it is very impure, containing about 4% of carbon. This carbon makes it very hard, but also very brittle. If you hit it hard, it tends to shatter rather than bend or dent. Cast iron is used for things like manhole covers, guttering and drainpipes, cylinder blocks in car engines, Aga-type cookers, and very expensive and very heavy cookware. Steel Most of the molten iron from a Blast Furnace is used to make one of a number of types of steel. There isn't just one substance called steel - they are a family of alloys of iron with carbon or various metals. More about this later . . .
Steel-making: the basic oxygen process Impurities in the iron from the Blast Furnace include carbon, sulphur, phosphorus and silicon. These have to be removed. Removal of sulphur Sulphur has to be removed first in a separate process.Magnesium powder is blown through the molten iron and the sulphur reacts with it to form magnesium sulphide. This forms a slag on top of the iron and can be removed.
Removal of carbon etc The still impure molten iron is mixed with scrap iron (from recycling) and oxygen is blown on to the mixture. The oxygen reacts with the remaining impurities to form various oxides. The carbon forms carbon monoxide. Since this is a gas it removes itself from the iron! This carbon monoxide can be cleaned and used as a fuel gas.
Elements like phosphorus and silicon react with the oxygen to form acidic oxides. These are removed using quicklime (calcium oxide) which is added to the furnace during the oxygen blow. They react to form compounds such as calcium silicate or calcium phosphate which form a slag on top of the iron.
Types of iron and steel Cast iron has already been mentioned above. This section deals with the types of iron and steel which are produced as a result of the steel-making process. Wrought iron If all the carbon is removed from the iron to give high purity iron, it is known as wrought iron. Wrought iron is quite soft and easily worked and has little structural strength. It was once used to make decorative gates and railings, but these days mild steel is normally used instead. Mild steel Mild steel is iron containing up to about 0.25% of carbon. The presence of the carbon makes the steel stronger and harder than pure iron. The higher the percentage of carbon, the harder the steel becomes. Mild steel is used for lots of things - nails, wire, car bodies, ship building, girders and bridges amongst others. High carbon steel High carbon steel contains up to about 1.5% of carbon. The presence of the extra carbon makes it very hard, but it also makes it more brittle. High carbon steel is used for cutting tools and masonry nails (nails designed to be driven into concrete blocks or brickwork without bending). You have to be careful with high carbon steel because it tends to fracture rather than bend if you mistreat it.
Special steels These are iron alloyed with other metals. For example:
iron mixed with special properties uses include stainless steel chromium and nickel resists corrosion cutlery, cooking utensils, kitchen sinks, industrial equipment for food and drink processing titanium steel titanium withstands high temperatures gas turbines, spacecraft manganese steel manganese very hard rock-breaking machinery, some railway track (e.g. points), military helmets
EXTRACTION PROCESS 23.3 Hydrometallurgy Hydrometallurgy is the extraction of metals from ores using water. These processes are usually more energy efficient than pyrometallurical processes. Leaching is the selective dissolution of the desired mineral. Typical leaching agents are dilute acids, bases, salts, and sometimes water.
3.4 Electrometallurgy Electrometallurgy of Sodium Electrometallurgy is the process of obtaining metals through electrolysis. Two different starting materials: molten salt or aqueous solution. Sodium is produced by electrolysis of molten NaCl in a Downs cell. CaCl2 is used to lower the melting point of NaCl from 804?C to 600?C. An iron screen is used to separate Na and Cl (so that NaCl is not re-formed).
Pyrometallurgy uses processes at high temperatures to obtain the free metal. Several steps are employed: Calcination is heating of ore to cause decomposition and elimination of a volatile product: PbCO3(s) ? PbO(s) + CO2(g)
Roasting is heating which causes chemical reactions between the ore and the furnace atmosphere: 2ZnS(s) + 3O2(g) ? 2ZnO(s) + 2SO2(g) 2MoS2(s) + 7O2(g) ? 2MoO3(s) + 4SO2(g) Smelting is a melting process that causes materials to separate into two or more layers.
Slag consists mostly of molten silicates in addition to aluminates, phosphates, fluorides, and other inorganic materials. Refining is the process during which a crude, impure metal is converted into a pure metal.
Most important sources of iron are hematite Fe2O3 and magnetite Fe3O4. Reduction occurs in a blast furnace. The ore, limestone and coke are added to the top of the blast furnace. Coke is coal that has been heated to drive off the volatile components. Coke reacts with oxygen to form CO (the reducing agent): 2C(s) + O2(g) ? 2CO(g) ?H = -221 kJ CO is also produced by the reaction of water vapor in the air with C: C(s) + H2O(g) ? CO(g) + H2(g) ?H = +131 kJ Since this reaction is endothermic, if the blast furnace gets too hot, water vapor is added to cool it down without interrupting the chemistry. At around 250?C limestone is calcined (heated to decomposition and elimination of volatiles).
Also around 250?C iron oxides are reduced by CO: Fe3O4(s) + 4CO(g) ? 3Fe(s) + 4CO2(g) ?H = -15 kJ Fe3O4(s) + 4H2(g) ? 3Fe(s) + 4H2O(g) ?H = +150 kJ Molten iron is produced lower down the furnace and removed at the bottom. Slag (molten silicate materials) is removed from above the molten iron. If iron is going to be made into steel it is poured directly into a basic oxygen furnace. The molten iron is converted to steel, an alloy of iron. To remove impurities, O2 is blown through the molten mixture. The oxygen oxidizes the impurities.
CALCINATION Definition: The process of subjecting absorptive mineral to prolonged heating at fairly high temperature, resulting in the removal of water, and an increase in the hardness, physical stability and absorbent properties of the material.
Calcination of limestone Abstract: A process for the continuous production of a calcined product containing a high level of reactive oxide valves, from a preheated raw material containing calcium carbonate values, said process comprising, (a) introducing the preheated raw material to the bottom of a generally vertically oriented gas suspension calcining furnace, whereby said preheated raw material is thereafter suspended in an ascending stream of heated gas to thereby pass vertically upwardly through the gas suspension calcining furnace; (b) passing the ascending gas stream through a plurality of burners, into which fuel and air are injected, that are vertically spaced from each other, in the gas suspension furnace, at a number of levels in the flow direction of the heated gas, and (c) collecting the calcin
Examples of chemical decomposition reactions common in calcination processes, and their respective thermal decomposition temperatures include: CaCO 3 = CaO + CO 2 ; 848C
ROASTING Definition: A process in metallurgy in which a sulfide ore is heated in air. The process may convert a metal sulfide to a metal oxide or to a free metal. Example- Roasting ZnS may yield ZnO; roasting HgS may yield free Hg metal. ed product. Roasting of sulphide ores- A method for roasting sulphide ores or ore concentrates containing precious metals is practiced in a furnace, typically in a fluidized bed. The ore and a sulphur-binding lime- containing material are supplied to a roasting furnace in which the ore is roasted with the emission of heat and sulphur dioxide. The lime-containing material--such as calcium hydroxide--is mixed into the cooling water for the roasting furnace and sprayed into the furnace as a lime-containing aqueous slurry. Roasting occurs at about 600-850 C. (e.g. 650- 750 C.). Roasted material is discharged from the furnace and acted upon to recover gold, silver and copper metal.
SMELTING Mined ores are processed to concentrate the minerals of interest. In the case of metal ores, these mineral concentrates usually need to be further processed to separate the metal from other elements in the ore minerals. Smelting is the process of separating the metal from impurities by heating the concentrate to a high temperature to cause the metal to melt. Smelting the concentrate produces a metal or a high- grade metallic mixture along with a solid waste product called slag.