Mat E 443

Ferrous Metallurgy
Iowa State Common metallic ores / sources
University
Fe
Hematite - Fe2O3 Russia, Brazil, China,
Australia, India, United
Magnetite - Fe3O4
States, France, Germany,
Ilmenite - FeTiO3 Spain, England
Limonite - FeO(OH) / HFeO2

Al
Canada, Russia, New
Bauxites Caldonia, Cuba, United
Gibbsite - Al2O33H2O States, South Africa
Bhmite/diaspore - Al2O3H2O

Cu Chile, Peru, Mexico,

Europe, South Africa,
chalcopyrite CuFeS2
several USA
bornite Cu5FeS4

Sn Malaysia, Thailand,
and Bolivia
Cassiderite SnO2
Stannite SnCu2(Fe.Zn)4

Caribbean area,
Ni South America,
Pentlandite [(Ni,Fe)9S8]. Australia and Africa
 Mat E 443
Ferrous Metallurgy
Iowa State Processing of metallic ores
University

Ore dressing or beneficiation practices:

Crushing / Grinding

Classifying / Sorting

Agglomerating
 Mat E 443
Ferrous Metallurgy
Iowa State Processing of metallic ores
University

Ore dressing or beneficiation practices:

Crushing / Grinding

Classifying / Sorting

Agglomerating
 Mat E 443
Ferrous Metallurgy
Iowa State Processing of metallic ores
University

Ore dressing or beneficiation practices:

Crushing / Grinding

Classifying / Sorting

Agglomerating
 Mat E 443
Ferrous Metallurgy
Iowa State Processing of metallic ores
University

Ore dressing or beneficiation practices:

Crushing / Grinding

Classifying / Sorting

Agglomerating
 Mat E 443
Ferrous Metallurgy
Iowa State Types of extraction processes
University

Pyrometallurgy Hydrometallurgy

Roast Roast

Smelt Leach

Convert Precipitate

Refine Refine

Processes may differ for reactive / nonreactive metals.

Nonreactive: Cu, Ni, Pb, Co, Au, Ag
Reactive: Al, Ti, Mg, Zn, Ur
 Mat E 443
Ferrous Metallurgy
Iowa State Types of extraction processes
University

Pyrometallurgy Hydrometallurgy

Roast Roast

Smelt Leach

Convert Precipitate

Refine Refine

In most cases, the metal-bearing ore is not in a chemical form that

from which the metal may be easily or economically removed by a
simple direct reduction. Roasting is a pretreatment reaction that
changes the ore to a more chemically useful form.
 Mat E 443
Ferrous Metallurgy
Iowa State Types of extraction processes
University

Pyrometallurgy Hydrometallurgy

Roast Roast

Smelt Leach

Convert Precipitate

Refine Refine

Smelting is a process where the charge is heated such that the metal
and dissolved impurities are separated as a liquid. Some of the
impurities in the charge are gathered into a light waste product called
a slag, which floats atop the molten metal.
 Mat E 443
Ferrous Metallurgy
Iowa State Types of extraction processes
University

Pyrometallurgy Hydrometallurgy

Roast Roast

Smelt Leach

Convert Precipitate

Refine Refine

During converting, the major impurities are removed from the melt,
typically by oxidation.
 Mat E 443
Ferrous Metallurgy
Iowa State Types of extraction processes
University

Pyrometallurgy Hydrometallurgy

Roast Roast

Smelt Leach

Convert Precipitate

Refine Refine

During refining, elemental, particulate, and gaseous impurities are

removed.
 Mat E 443
Ferrous Metallurgy
Iowa State Types of extraction processes
University

Pyrometallurgy Hydrometallurgy

Roast Roast

Smelt Leach

Convert Precipitate

Refine Refine

During leaching, the metallic element is leached from the solid ore
and dissolved in a solvent solution.
 Mat E 443
Ferrous Metallurgy
Iowa State Types of extraction processes
University

Pyrometallurgy Hydrometallurgy

Roast Roast

Smelt Leach

Convert Precipitate

Refine Refine

The metal is then precipitated in the metallic state from the

leaching solution.