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    This Lecture Metallurgy: (Extracting Metal From Ore) : - Extraction of Metals From Ores

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    This document discusses the process of metallurgy, or extracting metals from ores. It begins with general principles and then provides examples of mining copper and producing steel. Copper is extracted from sulfide ores by roasting to form oxides, which are then reduced using carbon. Steel production involves reducing iron oxide in a blast furnace with carbon monoxide to produce pig iron, which is further purified in the basic oxygen process using oxygen and lime. Key concepts covered include reduction of metal oxides, use of the Ellingham graph to predict reduction methods, and the detailed chemical processes for producing copper and steel from their ores.

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    This Lecture Metallurgy: (Extracting Metal From Ore) : - Extraction of Metals From Ores

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    hnl27
    67 views4 pages
    This document discusses the process of metallurgy, or extracting metals from ores. It begins with general principles and then provides examples of mining copper and producing steel. Copper is extracted from sulfide ores by roasting to form oxides, which are then reduced using carbon. Steel production involves reducing iron oxide in a blast furnace with carbon monoxide to produce pig iron, which is further purified in the basic oxygen process using oxygen and lime. Key concepts covered include reduction of metal oxides, use of the Ellingham graph to predict reduction methods, and the detailed chemical processes for producing copper and steel from their ores.

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    This document discusses the process of metallurgy, or extracting metals from ores. It begins with general principles and then provides examples of mining copper and producing steel. Copper is extracted from sulfide ores by roasting to form oxides, which are then reduced using carbon. Steel production involves reducing iron oxide in a blast furnace with carbon monoxide to produce pig iron, which is further purified in the basic oxygen process using oxygen and lime. Key concepts covered include reduction of metal oxides, use of the Ellingham graph to predict reduction methods, and the detailed chemical processes for producing copper and steel from their ores.

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    67 views4 pages

    This Lecture Metallurgy: (Extracting Metal From Ore) : - Extraction of Metals From Ores

    Uploaded by

    hnl27
    This document discusses the process of metallurgy, or extracting metals from ores. It begins with general principles and then provides examples of mining copper and producing steel. Copper is extracted from sulfide ores by roasting to form oxides, which are then reduced using carbon. Steel production involves reducing iron oxide in a blast furnace with carbon monoxide to produce pig iron, which is further purified in the basic oxygen process using oxygen and lime. Key concepts covered include reduction of metal oxides, use of the Ellingham graph to predict reduction methods, and the detailed chemical processes for producing copper and steel from their ores.

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    This lecture

    Extraction of metals from ores


    General principles, then
    Example: mining of copper Example: the Steel story

    Metallurgy: (Extracting metal from ore)


    Commercially important ores:

    Use thermochemistry and equilibrium to investigate how these chemicals/materials are produced.

    Good refs:

    Silberberg Chemistry, 3rd ed., pp.963-968 McMurray and Fay, Chemistry, 3rd ed., pp. 910-918

    Chemical composition of ores


    More ionic More covalent
    Ref: McMurray and Fay, p. 912

    Metallurgy: (Extracting metal from ore)


    One of Australias most important commodities

    How are metals extracted from ores? Mining Pre-treatment

    Chemical processing: mineral to compound Chemical processing: compound to metal Refining Alloying

    Pretreatment
    Several methods of pretreating the ore to obtain the mineral: Flotation, Cyclone, Magnetism, Leaching
    Lighter particles (gangue) Agitator

    Mineral to Compound
    The most common way to convert the mineral into a uniform chemical compound is to roast it in air, e.g. CaCO3(s) + heat CaO(s) + CO2(g) or 2ZnS(s) + 3O2(g) + heat 2ZnO(s) + 2SO2(g)

    Air

    Pulverised ore

    A source of acid rain.


    Froth, including mineral
    Ref: Petrucci, p.955

    Upward moving air stream

    Gangue

    Now sulfur oxides are scrubbed from smokestack, and recycled into sulfuric acid (see next lecture)
    Heavier particles (mineral)
    Ref: Chemical Storylines, p.282

    Ref: Silb., p.964

    Compound to Metal
    There are two main ways to form the pure metal from its oxide, depending on how reactive the metal is:
    a) Reduction with carbon (smelting, known since Egyptian times); b) Reduction with hydrogen (when carbide formation is a problem); c) Reduction with more active metal (when hydride formation is a problem); and Electrochemical reduction (known for about 150 years)

    Reduction with carbon


    Consider the formation reactions:
    (1) (2) (1)-(2) C(graphite) + 0.5O2(g) Zn(s) + 0.5 O2(g) Kp (300 K) 4.7x1023 2.3x1054 2.0x10-31

     ZnO(s) + more heat ZnO(s) + C(gr.) + heat  Zn(s) + CO(g)


    Temp (K) 500 750 1000 1250 1500 1750 Kp 3.4x10-15 7.3x10-7 1.8x10-2 2.6 1.4x103 9.0x104

     CO(g) + heat

    But
    Adding heat as a reagent

    Very Small. Favours reactants enormously! Le Chatelier at work!

    Reduction with carbon


    Ellingham diagram:
    100

    Reduction with C (other metals)


    Ellingham diagram:
    M.P. B.P.
    100

    80

    Zn(s) + 0.5 O2(g)

     ZnO(s)
    ln Kp

    Ca - CaO Al - Al2O3

    M.P. B.P.

    80

    Note ln scale

    60

    60

    40

    ZnO Zn
    C CO

    40

    1RWLFH RUGHU RI HOHPHQWV


    Zn - ZnO Fe - FeO Ni - NiO
    600 800 1000 1200

    ln Kp

    20

    C - CO

    C(graphite) + 0.5O2(g)
    0 400 600 800 1000

     CO(g)
    1200 1400 1600 1800

    20

    0 400

    1400

    1600

    1800

    Temperature (K)

    Temperature (K)

    Reduction with C (other metals) Compound to Metal


    Is there a chemical explanation for this trend? Metal Ca Al Zn Fe Ni Electron-attracting power of an element (in a compound) Most stable oxides

    Electronegativity 1.0 1.5 1.6 1.8 1.9

    Metal Least active Au, Pt Cu, Ag, Hg, Ni, Co V, Cr, Mn, Fe, Ti, Sn Most active Al, Li, Na, Mg

    Reduction Method None; found in nature as free metal Roast sulfide to oxide reduction using carbon, hydrogen, or more active metal electrolysis

    Oxygen is very electronegative. Which elements most readily give up their electrons to form stable oxides?

    Example: Production of Copper


    Copper has been mined since ancient times, maybe 3500 BC Copper deposits formed in magma pools and occur mostly as sulfides, CuS Near the surface, the minerals are altered by exposure to oxygen, into other minerals, e.g. cuprite (Cu2O), tenorite (CuO), malachite, Cu2(OH)2CO3

    Example: Production of Copper


    Surface deposits of copper oxides soon ran out. Larger deposits of sulfides were available. Sulfides converted to oxides by roasting.

    Cu2S(s) + 1.5 O2(g) + heat

     Cu O(s) + SO (g)
    2 2

    Formation reaction for oxide: Cu(s) + 0.5 O2(g) Kp =4.3x1022 ln(K) = 52.1 electronegativity = 1.9

     CuO(s) + heat
    T T

    Largest deposits of copper are chalcopyrite, which contain iron Chalcopyrite is ground, then froth flotation is used to separate mineral from gangue T The sulfide is smelted directly to Cu metal

    Look back at Ellingham plot and electronegativity table and predict how the ancients might have reduced CuO.

    Example: Production of Copper


    Waste gases, SO2 Chalcopyrite + silica (SiO2) Fuel Slag Copper (impure, 2% S) electrolytic Overall reaction: refining 4CuFeS2(s) + 10.5O2(g) 4Cu(s) + 2FeO(l) + Fe2O3(s) + 8SO2(g) Oxide

    Example: The Steel Story


    Iron/steel is the most widely used of all metals, with some 750 million tonnes per year produced worldwide. Iron has been smelted since ~1500 BC In 1773, a cheap process to produce coke (carbon) from coal, and the advent of the blast furnace, led to large-scale iron production and the Industrial Revolution. Important iron minerals: Mineral type Mineral, formula Hematite, Fe2O3 Magnatite, Fe3O4 Ilmenite, FeTiO3 Carbonate Sulfide Siderite, FeCO3 Pyrite, FeS2 Pyrrhotite, FeS

    O2

    Example: The Steel Story


    The overall reaction uses CO as reducing agent:

    Example: The Steel Story


    Ore, CaCO3, C Temp

    Fe2O3(s) + 3CO(g) 2Fe(l) + 3CO2(g)


    Solids drop Hot gases rise

    But this is the overall reaction and hides a multitude of processes. The process of converting iron ore into iron and steel involves a series of reductions of the ore, and acid-base steps. Although these seem simple enough, the detailed chemistry is very complex, and perhaps not fully understood even now.
    Iron Forge (1772) Joseph Wright of Derby

    3Fe2O3 + CO 2 Fe3O4 + CO2 Fe3O4 + CO 3FeO + CO2 CaCO3 CaO + CO2 C + CO2 2 CO FeO + CO Fe + CO2 Impure iron melts. Molten slag forms 2C + O2 2 CO

    200C

    700C 1200C 1500C 2000C

    Hot air blast Slag Molten iron


    Slag floats on iron, like Earths crust on core

    Example: The Steel Story


    The iron from the furnace is impure and called pig iron. Pig Iron Bob It contains typically 3-4% carbon Iron is purified and converted to steel by the basic oxygen process.

    Example questions
    CONCEPTS
    reduction of metal oxide use of Ellingham graph knowledge of the production of Cu, steel

    High pressure O2 is blown over the molten iron. Impurities with very stable oxides form (e.g. C, Si, P, Mn, S) It is too hot for less stable oxides, including iron.) CaO (lime) is added, which reacts with these oxides to form a variety of phosphates, silicates, etc, all termed slag, which again float on the surface of the molten steel. Now 1% C, and very low other impurities and ready to alloying, e.g. Cr. to make stainless steel.
    Ref, Silberberg, p.972

    CALCULATIONS
    Equilibrium and thermochemistry calculations involving metallurgy.

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