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/ 17
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Principles of
Extractive
Metallurgy
|
ae Tee
HLS. Ray at. air |
A. Ghosh atte, |
#) NEW AGE INTERNATIONAL PUBLISHERS .
so tice PRINCIPLES OF
EXTRACTIVE METALLURGY
[SECOND EDITION]
AHINDRA GHOSH
Professor
Department of Metallurgical Engineering
Indian Institute of Technology
Kanpur
HEM SHANKER RAY
Director
Regional Research Laboratory
Bhubaneswar
and
Professor (on leave)
Department of Metallurgical Engineering
Indian Institute of Technology
‘Kharagpor
°
PUBLISHING FOR ONE WORLD
NEWAGE INTERNATIONAL (P) LIMITED, PUBLISHERS
(formerly Wiley Eastern Limited)
New Delhi + Bangalore + Chennai + Cochin * Guwahati « Hyderabad
Jalandhar * Kolkata + Lucknow * Mumbai + Ranchi
Visit us at www.newagepublishers.com Copyright © 1991, 1984, New Age International (P) Ltd., Publishers
Published by New Age International (P) Ltd., Publishers
First Edition: 1984
‘Second Edition: 1991
Reprint: 2010
All rights reserved.
No part ofthis book may be reproduced in any form, by photostat, microfilm, xerography,
or any other means, or incorporated into any information retrieval system, electronic or
‘meclianical, without the written permission of the copyright owner.
Branches:
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ISBN (10) : 81-224-0322-0
ISBN (13) : 978-81-224-0322-0
Rs, 195.00
C-10-04-4548
Printed in India at Nisha Enterprises, Delhi.
PUBLISHING FORONE WORLD
NEWAGE INTERNATIONAL () LIMITED, PUBLISHERS
4835/24, Ansari Road, Daryaganj, New Delhi-110002
Visit us at www.newagepublishers.com TO PARENTS
(Late) Bejoy Panchanan Ghosh
Labanyamoyee Ghosh
and
Benoy Bhushan Ray
Mrinmayee Ray FOREWORD
Towards achieving its objectives of promoting and advancing the ant, science
and technology of making, shaping and treating of metals and alloys, the Institute
has been considering publishing text-books on various metallurgical engineering
subjects. Lack of good text-books have made it difficult for the students appearing
in the Associate Membership Examination of the Institute to keep themselves
abreast of developments in the field of Extractive Metallurgy with special reference
to Indian conditions. Besides, foreign books on various subjects are invariably
costly and difficult to obtain. The Metal Sciences Division of the Institute which
is concerned with research and development of metals and materials, took the
initiative and suggested that the Institute could bring out a series of modules in
the form of text-books for undergraduate students and particularly for AMIIM
students. It was, at the meeting held on November 16, 1980 chaired by my
predecessor Mr. C.V. Sundaram of Bhabha Atomic Research Centre, a final
decision was taken to bring out two books—one on ‘Principles of Physical
Metallurgy’ and another on-‘Principles of Chemical Metallurgy’, to start with.
At that time, Prof. A. Ghosh who had authored a comprehensive note on ‘Principles
of Extractive Metallurgy’, was approached by the undersigned with a request to
author the book on ‘Principles of Extractive Metallurgy’. After getting his consent,
the matter was taken up with the Council of the Institute. The Council in its meeting
on 8th February 1982 agreed in principle to publish this book under the banner
of the Institute. Accordingly, the Meta! Sciences Division has utilised the valuable
Contributions made by Dr. A Ghosh and Dr. H.S. Ray to bring out the first book
entiled ‘Principles of Extractive Metallurgy* on a trial basis. This book is very
well designed and planned to cover the*requirements of the course on ‘Principles
of Extractive Metallurgy’ at the undergraduate Degree course in Metallurgical
Engineering in India and abroad. Some parts of the book will be useful even at
the postgraduate level, Extractive Metallurgy is an important subject in Metallurgy
which is generally less emphasised at the undergraduate level in most of the
countries including India. There is also no single good book covering all aspects
of ‘Principles of Extractive Metallurgy’.
T have.no doubt that the present book, the first of its kind published by the
Institute, will be able to fill up this void and will gain great popularity amongst
the students of Metallurgy and others interested in Extractive Metallurgy.
Dr. AK. Seal
Ex-Chairman,
Metal Sciences Division,
and
Ex-President
The Indian Institute of Metals PREFACE TO THE SECOND EDITION
The first edition of the book was well-received. Morcover there is no book
yet in the market which has the approach used in this text. It covers a variety
of principles in a nutshell so as to provide an integrated view of Extractive
Metallurgy as a discipline in Engincering, The objective all through has been
elucidation of basic concepts in an introductory fashion and in a manner which
would suit students, researchers and practising metallurgists.
Therefore it was decided to bring out a second edition. Since the Indian
Institute of Metals, which brought out the first edition, is not geared for large scale
publication and marketing of the same, it was undertaken by the present publisher.
The authors wish to thank the Indian Instituwe of Metals for giving up their copyright
claim in the larger interest of the profession.
In the second edition, some minor changes in contents have been made, The
text has been extensively edited. Emphasis has also been given in clarification
of points where scope existed, Answers to problems have been added and some
more recent references have been incorporated.
Ahindra Ghosh
Hem Shanker Ray PREFACE TO THE FIRST EDITION
The authors have been engaged in the teaching of various aspects of
Extractive and Chemical Metallurgy for nearly two decades. During the course
of teaching they have consistently felt the need for a book on the principles of
the subject for metallurgy students in the country. Several years ago the first author
had cyclostyled some of his lecture notes on the Principles of Extractive Metallurgy
which were welt seceived by students as well as many professional colleagues.
The present book owes its origin to those preliminary notes. The scope, content
and coverage, of this book, however, are much more extensive.
There are a good number of books on the subject in the market now. These.
can be put into three distinct categories. Books in the first category deal with unit
processes in a descriptive manner. Another category of books deal with physical
chemistry aspects of metallurgical reactions and processes emphasising primarily
thermodynamics. This approach had gained considerable popularity at one time,
specially in the area of ferrous metallurgy. In the third category, there are only
limited number of books where Extractive Metallurgy is dealt as an engincering
discipline akin to chemical engineering. We accept this as the best approach and
this book has been written accordingly. However, some useful features of the other
approaches have also been included.
The present book contains brief descriptive summary of some important
metallurgical unit processes. Subsequently it discusses not only the physical
chemistry of metallurgical reactions and processes but also rate phenomena
including heat and mass transfer, fluid flow, mass and energy balance, elements
of reactor engineering. A variety of scientific and engineering aspects of unit
processes have been discussed with stress on the basic principles throughout. There
is an attempt to introduce, as much as possible, quantitative weatments and
engineering estimates. The latter may often be approximate from the point of view
of theory but yield results that are very valuable to both practising metallurgists
as well as others,
While the book is meant primarily for the undergraduate students, it assumes
that the reader has been previously exposed to Metallurgical Thermodynamics
and elementary transpon-phenomena, The book can serve as a text book for a
single course if the students are already familiar with the first principles of the
various topics covered. Alternatively, the various Chapters can be used in the
teaching of different courses. All undergraduate Metallurgy Departments in the
country offer separate courses in Metallurgical Thermodynamics and several of
them also offer courses on heat, mass and momentum transfer, kinetics and electro-
and hydrometallurgy. It is hoped that this book will be useful in all these courses.
‘The authors hope that the book will prove useful also to graduate students,
researchers and professional colleagues and serve as a ready reference for basic
concepts in the areas relevant to Extractive Metallurgy.
‘The book starts with an overview of some definitions and descriptions of
some important extraction and refining processes so that principles to be discussed
later are better understood with respéct to actual processes. The first two chapters
thus form the Introductory Part A. Part B, consisting of seven chapters from 3
to 9 deals largely with Principles of Pyrometallurgy although some concepts Preface to the First Edition
discussed are equally applicable elsewhere. The rcason for this emphasis on
Pyrometallurgy should be self evident. Afier all, bulk of common metals is still
produced by high temperature operations. Part C consisting of Chapters 10 and
11 summarizes the principles of Electro-and Hydrometallurgy.
Dispersed throughout the text are many solved examples to elucidate the
theory. At the end of cach chapter is a list of general reading and references and
also some questions and/or problems. Numerical figures and calculations are in
SI units. There are a list of contents, a list of symbols and a subject index for
ready reference. There is also some useful information in the Appendix. The figures
generally follow their first mention in the text. To reduce the bulk, some separate
figures have been printed in single pages, In such cases, the figures follow the
first mention in the text of the lust figure. The reader is, therefore, requested 10
flip through some more pages in case the required figure does not follow
immediately.
‘The authors will consider their labour rewarded if the book proves useful
to students and colleagues interested in Extractive Metallurgy.
Ahindra Ghosh
November 1982 Hem Shanker Ray ACKNOWLEDGEMENT
While the authors were looking for publisher for the first edition, the Indian
Institute of Metals (IM) came forward and readily ook wp the publication work.
The authors received wholehearted cooperation from the Council and the office
bearers of the ITM in this endeavour. As a result, the first edition of the book could
‘be published by the Indian Institute of Metals in 1984. The authors are grateful
to all of them especially to Professor AK. Seal, the then Chairman, Metal Sciences
Division of the Indian Institute of Metais for encouragement and for writing a
Foreword to the fisst edition.
During preparation of the manuscript for the first edition the authors received
help, aclvice and suggestions from several colleagues and students both at the Indian
Institute of Technology, Kanpur and Indian Institute of Technology, Kharagpur.
We are grateful 10 all of them.
Finally the authors wish to thank their wives, Dr. (Mrs.) Radha Ghosh and
Mrs. Chitra Ray for their cooperation and patience during the period of writing.
Ahindra Ghosh
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LIST OF SYMBOLS
activity, constant, acceleration
activity of species i
frequency factor, surface area, ampere.
Biot's number
centipoise
concentration, specific heat, velocity of light
specific heat at constant pressure
specific heat at constant volume
diameter, draft in furnace
particle diameter, diffusion coefficient
roughness of pipe wall, electron
interaction coefficient describing influence of j on activity
coefficient of i in weight percent scale
electrode potential, activation energy, internal energy, extraction
coefficient
eddy conductivity, activation energy for conduction
Henrian activity coefficient
fraction of reaction completed, force, Faraday constant
view factor
Fourier’s number
gram, acceleration due to gravity
free energy
a finite change in free energy
standard free energy
partial molar free energy of species i
Grasshoff’s number
heat transfer coefficient, Planck’s constant, Henrian activity, hour
enthalpy, heat content
constituent of a solution, current density
current
constituent of a solution
Joule
rate constant of a reaction
mass transfer coefficient
Boltzmann's constant
equilibrium constant
length
Jength, characteristic length
mass
Mass, molecular mass, symbol for metal
number of mols
rate in mols per unit time
Avogadro's number
Nusselt’s number
Partial pressure of species i
total pressure
Prandul’s number
volumetric flow rate
radius O N¥
