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Pyrometallurgy 1

The document discusses various methods used in the extraction of metals from ores, including calcination, roasting, smelting, and refining. [1] Roasting involves heating sulfide ores in air below their fusion temperature to partially or fully oxidize the sulfide and remove sulfur. [2] Various roasting techniques are described, including multiple hearth furnaces, flash roasting, fluidized bed roasting, and sintering machines. [3] Sintering is used to both roast lead sulfide concentrates to remove sulfur and partially melt the materials to form a porous, cohesive cake suitable for blast furnace processing.

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Athlur Sai Kiran
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63 views

Pyrometallurgy 1

The document discusses various methods used in the extraction of metals from ores, including calcination, roasting, smelting, and refining. [1] Roasting involves heating sulfide ores in air below their fusion temperature to partially or fully oxidize the sulfide and remove sulfur. [2] Various roasting techniques are described, including multiple hearth furnaces, flash roasting, fluidized bed roasting, and sintering machines. [3] Sintering is used to both roast lead sulfide concentrates to remove sulfur and partially melt the materials to form a porous, cohesive cake suitable for blast furnace processing.

Uploaded by

Athlur Sai Kiran
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Basic theory of

Extraction

Dr. SB Arya, MME


NITK Surathkal
Calcination

Roasting

Smelting

Refining
Calcination : Mineral/ ore of the metal is heated to high temperature in
the absence or limited supply of air or oxygen

Uses :
ROASTING
Sulphide ores are in general difficult to reduce to metal.
Therefore, it is desirable to convert the sulphide form of the ore
to oxide form, which is suitable for reduction.

This conversion is carried out by heating the sulphide ore below


its fusion temperature with excess of air.
A sulfide ore or concentrate is subjected to roasting in
order to achieve one or more of the following
objectives:

(i) partial oxidation causing loss of part of the sulfur


content;
(ii) oxidation to sulfates, which is essentially called
sulphation roasting; and
(iii) complete removal of sulfur, i.e., conversion to
oxides, which is essentially called dead roasting.
Roasting practice
Thermodynamics of roasting

Predominance area diagram at a constant


temperature for the M─S─O system. Lines
describing the equilibrium between any two
condensed phases are given by equations:
Effect of temperature on equilibria and predominance areas in the M─S─O
system at constant pressure of SO2 gas

Normally, with increase of


temperature sulfide gets roasted to
oxide along the path shown by the
curve (a).

Toward the end of the roasting process when temperature falls, some sulfate may be
formed. In the second case presented by the curve (b), during roasting, first the sulfate
is formed at low temperature. If temperature increases by means of additional heat it
decomposes to oxide.
Roasting of zinc sulfide concentrates
Roasting of PbS concentrates
Type of roasting furnace

• Multiple-hearth type roasting furnace


• flash roaster
• Fluidized bed roasting
• Sintering machine (or blast roaster).
The multiple hearth furnaces

Multiple Hearth Roaster MacDougall in England (19th Centaury)


Counter current flow of solid ore & the oxidizing gases - diameter = 25 ft, 6 to
12 hearth - Steel shell lined with cylindrical brick - Ore is charge from top

The multiple hearth furnaces consist of several circular hearths or kilns superimposed on each other. Material is fed from
the top and is moved by the action of rotating "rabble arms", and the revolving mechanical rabbles attached to the arms
move over the surface of each hearth to continuously shift the ore. The arms are attached to a rotating central shaft that
passes through the center of the roaster. As the material is moved, the ore that is charged at the top hearth gradually moves
downward as it passes through windows in the floor of each hearth or through alternate passages around the shaft and the
periphery until it finally emerges at the bottom.
Flash roaster

Flash roasters are a new concept and are used when pre-cooked products need to have a
roast finish. It is a quick process and allows products such as hams to be ‘roasted’ in under
three minutes and are still cool enough to be packed.
Flash roaster

Combustion chamber

Waste gases

Discharging devices

Roasted products
Fluidized bed roasting
Fluidized bed roasting
Sintering
The purposes of sintering are:
• to roast lead sulfide concentrates so as to remove sulfur, and
• to achieve sufficient temperature to cause partial melting in order to form a porous
cake of sufficient
cohesion and strength to be suitable as feed to the blast furnace.
Sintering

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