The Extraction and Refining of Metals

Description

The Extraction and Refining of Metals provides a novel approach to the science and technology of both ferrous and non-ferrous metal production. Rather than the traditional treatment in which one metal at a time is considered, this new approach, which examines several metals at a time, reveals more clearly the versatility and limitations of each of the main types of process. The restrictions imposed on the selection of the process routes by thermodynamic and kinetic factors and by economic and environmental constraints are examined in detail. The conservation of energy and materials is emphasized and illustrated by the description of new and improved extraction methods. The types of mathematical models that are being developed for computer control of production operations are indicated, and worked examples demonstrate relevant thermodynamic and mass balance calculations. Content: Cover Half Title Title Page Copyright Page Table of Contents Preface List of Symbols Chapter 1: The Economics of Metal Production 1.1. The Cost of Metals 1.2. Mineral Deposits 1.2.1. Average Concentrations of Metals 1.2.2. Igneous Intrusions 1.2.3. Sedimentary Deposits 1.2.4. Workable Deposits 1.3. Mineral Dressing 1.3.1. Comminution 1.3.2. Separation 1.4. Agglomeration 1.4.1. Pelletizing 1.4.2. Sintering 1.4.3. Sintering versus Pelletizing 1.5. Reduction and Refining 1.5.1. Pyrometallurgy 1.5.2. Hydrometallurgy 1.5.3. Electrometallurgy 1.6. Choice of Process 1.7. Typical Production Routes1.7.1. Aluminum 1.7.2. Iron 1.7.3. Copper 1.7.4. Lead 1.7.5. Tin 1.7.6. Zinc 1.7.7. Other Metals 1.8. Factors Affecting the Price of Metals 1.8.1. Cost 1.8.2. Price Further Reading Chapter 2: Theoretical Principles-1, Thermodynamics 2.1. Thermodynamic Relations 2.1.1. Thermodynamic Systems 2.1.2. Free Energy, Enthalpy and Entropy 2.2. Solutions 2.2.1. Partial Molar Free Energy 2.2.2. Fugacity 2.2.3. Activity 2.2.4. The Equilibrium Constant 2.2.5. Solution Models 2.2.6. Dilute Solutions 2.2.7. Alternative Standard States 2.2.8. Multicomponent Solutions2.3. Graphical Representation of Thermodynamic Data 2.3.1. Phase Diagrams 2.3.2. Free Energy-Temperature Diagrams 2.3.3. Predominance Area Diagrams 2.3.4. Pourbaix Diagrams 2.3.5. Other Diagrams and Applications Chapter 3: Theoretical Principles-2, Kinetics 3.1. Chemical Reaction Kinetics 3.1.1. Kinetic Theory 3.1.2. Reaction Rate Theories 3.2. Transport Kinetics 3.2.1. Diffusion 3.2.2. Heat Transfer 3.2.3. Mass Transport 3.3. Reactions Across Interfaces 3.3.1. Gas-Liquid Reactions 3.3.2. Gas-Solid Reactions 3.3.3. Liquid-Liquid Reactions 3.4. Nucleation3.4.1. Nucleation of Precipitates 3.4.2. Nucleation of Gas Bubbles Further Reading Chapter 4: Pyrometallurgical Extraction 4.1. Reducing Agents 4.1.1. Carbon Reduction 4.1.2. Hydrogen Reduction 4.1.3. Metallothermie Reduction 4.2. Roasting 4.2.1. Dead Roasting 4.2.2. Environmental Constraints 4.3. Agglomeration 4.3.1. Sintering 4.3.2. Pelletizing 4.4. Carbothermic Reduction 4.4.1. The Blast Furnace Process 4.4.2. Carbothermic Reduction without Coke 4.5. Reduction of Sulfide Ores 4.5.1. Treatment of Copper Sulfides 4.5.2. Treatment of Nickel Sulfides 4.5.3. Treatment of Lead Sulfides4.6. Reduction of the More Reactive Metals 4.6.1. Metallothermie Reduction of Magnesium 4.6.2. The Halide Extraction Route Further Reading Chapter 5: Pyrorefining 5.1. Objectives and Principles 5.1.1. Overview 5.1.2. Standard Specifications 5.1.3. Partition Ratios 5.1.4. Refining Kinetics 5.2. Refining Slags 5.2.1. Slag Structures 5.2.2. Thermodynamic Properties 5.3. Slag-Metal Reactions 5.3.1. Iron Refining 5.3.2. Steelmaking Practice 5.4. Metal-Metal Equilibria 5.4.1. Liquation and Drossing 5.4.2. Deoxidation 5.5. Metal-Gas Reactions