Extractive metallurgy is the art and science of extracting metalsfrom their ores and refining them. The production of metals andalloys from these source materials is still one of the mostimportant and fundamental industries in both developed anddeveloping economies around the world. The outputs and products areessential resources for the metallic, mechanical, electromagnetic,electrical and electronics industries (silicon is treated as ametal for these purposes).
This series is devoted to the extraction of metals from ores,concentrates (enriched ores), scraps, and other sources and theirrefining to the state of either liquid metal before casting or tosolid metals. The extraction and refining operations that arerequired may be carried out by various metallurgical reactionprocesses.
Extractive Metallurgy 1 deals with the fundamentals ofthermodynamics and kinetics of the reaction processes. ExtractiveMetallurgy 2 focuses on pyrometallurgical, hydrometallurgical,halide and electro-metallurgical (conversion) processes. ExtractiveMetallurgy 3 deals with the industrial processing operations,technologies, and process routes, in other words the sequence ofsteps or operations used to convert the ore to metal. Processes andoperations are studied using the methodology of "chemicalreaction engineering".
As the fundamentals of the art and science of ExtractiveMetallurgy are infrequently taught as dedicated university orengineering schools courses, this series is intended both forstudents in the fields of Metallurgy and Mechanical Engineering whowant to acquire this knowledge, and also for engineers put incharge of the operation of an industrial production unit or thedevelopment of a new process, who will need the basic knowledge ofthe corresponding technology.
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ISBN-13
978-1-118-61702-1 (9781118617021)
Schweitzer Klassifikation
Preface xi
Chapter 1. Physical Extraction Operations 1
1.1. Solid-solid and solid-fluid separation operations 1
1.2. Separation operations of the components of a fluid phase5
1.3. Bibliography 12
Chapter 2. Hydrometallurgical Operations 15
2.1. Leaching and precipitation operations 15
2.2. Reactor models based on particle residence timedistribution functions 24
2.3. Reactor models based on the population balance equationmodel 30
2.4. Solvent extraction operations 34
2.5. Bibliography 43
Chapter 3. Gas-solid and Solid-solid Reactors and ParticleConversion Operations 45
3.1. Overall presentation of gas-solid and solid-solid reactors45
3.2. Gas-solid reactor hydrodynamic behavior and heat transferbetween phases 47
3.3. The performance equations of gas-solid packed-bed reactors55
3.4. The performance equations of fluidized-bed reactors 65
3.5. Solid-solid reactors 73
3.6. Bibliography 77
Chapter 4. Blast Furnaces 79
4.1. Overview of blast furnaces 79
4.2. Iron blast furnace 81
4.3. Ferromanganese blast furnace 109
4.4. Zinc blast furnace: the Imperial smelting furnace 114
4.5. Lead blast furnace 120
4.6. Bibliography 122
Chapter 5. Smelting Reduction Operations 125
5.1. Overview of smelting reduction operations 125
5.2. Production of (iron) "hot metal" bycarbothermic smelting reduction 126
5.3. Tin and zinc smelting reduction operations 139
5.4. Magnetherm process 146
5.5. Bibliography 148
Chapter 6. Steelmaking Operations 151
6.1. Overview of steelmaking operations 151
6.2. Hot metal pretreatment operations 153
6.3. The hot metal converting operation 154
6.4. Stainless steelmaking operations 174
6.5. Ultra-low carbon steel-making operation 179
6.6. Bibliography 183
Chapter 7. Sulfide and Matte Smelting and ConvertingOperations 185
7.1. Overview of the operations and processes 185
7.2. Flash-smelting operations and processes 188
7.3. In-bath smelting and converting operations in bottom-blownconverters 195
7.4. In-bath smelting and converting operations in top-blownconverters 203
7.5. Top-submerged lance (TSL) blown converters:Ausmelt/Isasmelt process 208
7.6. Bibliography 213
Chapter 8. Electric Melting and Smelting Furnaces 217
8.1. Introduction 217
8.2. Performance of electric furnaces 220
8.3. Electric arc melting furnaces 235
8.4. Electric smelting reduction furnaces 240
8.5. Consumable-electrode remelting furnaces 257
8.6. Bibliography 261
Chapter 9. Molten Salt Electrolysis Operations 265
9.1. Overview of molten salt electrolysis operations 265
9.2. Chloride electrolysis 266
9.3. Reduction of alumina by electrolysis 271
9.4. Electro-reduction of metal oxides and deoxidation of metalsby molten salt electrolysis 286
9.5. Bibliography 289
Chapter 10. Extractive Processing Routes 293
10.1. Features of extractive processing routes 293
10.2. Hot metal, steel and ferroalloys 296
10.3. Aluminum (gallium) 298
10.4. Copper and other valuable metals 300
10.5. Nickel (cobalt) 304
10.6. Zinc (cadmium, indium, germanium, gallium) 311
10.7. Lead (silver, gold, bismuth) 314
10.8. Tin 316
10.9. Magnesium 318
10.10. Titanium, zirconium and hafnium 318
10.11. Chromium 321
10.12. Molybdenum and tungsten 321
10.13. Niobium and tantalum 322
10.14. Gold 323
10.15. Metals belonging to the PGM 324
10.16. Silicon 324
10.17. Bibliography 325
List of Symbols 329
Index 341
Summaries of Other Volumes 353
