Introduction | Principles of Metallurgy | Engr. Q.Balidoy

1. >Geology - ore discovery
    >Mining - ore digging
    >Metallurgy - ore processing

2. What is metallurgy?

It is the science and art
of extracting,
refining, and
adopting
metals from minerals, 
at a PROFIT,
for human use,
with the utmost care for the environment.

3. Basic terms and concepts:

MINERALS - chemical compounds in the earth's crust containing metals

ORE - a rock which contains minerals from which metals may be profitably recovered

ORE DRESSING - the preparation required before the extraction process

EXTRACTION - the recovery of the metal from the ore (or mineral)

UNIT OPERATIONS - the individual sequential steps in producing metal
from the ore involving purely physical changes

UNIT PROCESSES - the individual sequential steps in producing a metal
 involving chemical reactions and/or changes in the state of aggregation

WINNING - the processes involved in removing and collecting the metals from ore

CONCENTRATE - the valuable minerals obtained from the recovery process

GANGUE - the minerals of no value

4. GEOLOGY>MINING>METALLUGY>MINERAL PROCESSING

MINERAL PROCESSING: HYDROMETALLURGY, PYROMETALLURGY, ELECTROMETALLURGY

HPE > METALS FORMING PROCESSES > PROPERTY MODIFICATION PROCESSES

METALS FORMING PROCESSES
-mechanical metallurgy
-foundry metallurgy
-powder metallurgy

PROPERTY MODIFICATION PROCESSES
-physical metallurgy
-microscopic characterization
-mAcroscopic characterization
-alloying
-heat treatment

5. Branches of Metallurgy

• MINERAL PROCESSING
• EXTRACTIVE METALLURGY
• PHYSICAL METALLURGY
• ADAPTIVE METALLURGY

MINERAL PROCESSING
-extraction of the valuable mineral from the ore

EXTRACTIVE METALLURGY
-extraction of metal from the metal from the mineral

PHYSICAL METALLURGY
-deals with the relationship of properties and structures of metals and alloys

ADAPTIVE METALLURGY
-making metal conform to application

6. ORE DRESSING

Perspective in metallurgy: WE NEED METALS, PRIMARY SOURCE OF MINERALS

GOLD PROJECTS:
-MASBATE
-NORTH DAVAO
-APEX
-NRMDC's DIWATA

COPPER PROJECTS:
-BATONG-BUHAY
-FAR SOUTH EAST
-DIDIPIO
-MARCOPPER
-ATLAS
-MARICALUM
-PHILEX's BAYONGAN
-COLET
-KINGKING
-TAMPAKAN

NICKEL PROJECTS:
ERAMEN
MINDORO
RIO TUBA EXPANSION
PHILNICO
ADLAY-CAGDIANNAO-TANDAWA
TAGANITO EXPANSION
PUJADA

7. TECHNOLOGY

*GOLD

MILLER PROCESS

• CHLORINE GAS IS PASSED THROUGH MOLTEN GOLD TO PRECIPITATE OTHER METALS
• >99.5 % Au

WOHLWILL PROCESS

• SELECTIVE DEPOSITION OF GOLD USING REDOX
• >99.99%  Au 

CIP / CIL / CIC

• SELECTIVE DISSOLUTIONS OF GOLD USING CYANIDE
• >0.3% Au FEED

Direct Smelting - Slag formation for removal of Au impurities

Merrill-Crowe Process:  Zinc-Dust Precipitation of Au impurities

*NICKEL

HPAL:  H2SO4 Leaching of Ni into sulfate at ↑T, ↑P  0.8% Ni → 57% Ni

Moa Bay Process:  H2SO4 Leaching of Ni into sulfate

Sherritt Gordon Process:  NH3 Leaching of Ni

Direct Smelting:  Slag formation for removal of Ni impurities

*COPPER

Heap Leaching:  H2SO4 Leaching of Cu into sulfate  >0.1% Cu Feed

Flash Smelting:  Autogenous Fine particle smelting of Cu  >30% Cu feed

Mitsubishi Process:  Continuous Furnace Smelting of Cu

Electro-Refining:  Selective deposition of Cu by winning  99.99% Cu product

*IRON

Blast Furnace Smelting:  Iron Smelting

Midrex / COREX Process:  Direct Iron Oxide Reduction

Basic Oxygen Furnace Smelting:  Selective oxidation of Fe Impurities

8. PROBLEM

TECHNICAL: Sensitivity of the processes!

ECONOMIC: Cut-off Grades!

Bridging the Gap
 Mineral Processing “de-stresses” the transition between the mineral source, to the final metal product!

8. MINERAL PROCESSING/ MINERAL BENEFICIATION/ ORE DRESSING

 The mechanical separation of valuable minerals from the valueless material of an ore
 The valuable mineral is collected into a smaller bulk WITHOUT altering the physical and chemical identity of the minerals
 Treatments applied to the ore containing valuable metallic or nonmetallic minerals prior to recovery and separation

9. RATIONALE

 Virtually, no mineral, AS MINED, is suitable for conversion to final product
 Rather, it requires preparation of ores by physical methods

10. Objectives of Ore Dressing

 Technical 
 To bring the valuable mineral or the final product into suitable technical condition as required by the process
 Undesired constituents of the original ore must be removed or reduced below the specified units

 Economic 
 To provide the cheapest way to eliminate the unwanted minerals
 Reduce unit material handling costs

11. Economic Criteria

 Mineral Processing must be cost efficient!
 If an ore or mineral is not marketable w/o MP, the processing operation will not be justified unless the product has a selling price GREATER than all the costs involved in producing it

PROFIT = (Metal Price) – (Mining + MinProc + Others) = if (+), OK!

12. Benefits from Mineral Processing

 Concentration of desired mineral = Freight Savings!
 Since little or no waste is being shipped in the concentrate, quite considerable freight savings can be realized

 Waste Rock Minimization = Improved Metal Purity!
 Since the waste in the shipment has been considerably reduced, metal losses in slag or leaching residues are correspondingly reduced

 Effective Material Reduction = Reduced Treatment Charges!
 The reduced tonnage of materials to be treated, either by smelting or leaching, results in drastic reductions of treatment charges

 When concentration methods are both efficient and cheap, it is often possible to take advantage of low-cost, high tonnage mining methods to produce ores of lower grade than would normally be produced by high-cost selective mining methods

 Efficient and low-cost mineral processing plants make it possible to treat material which, without the availability of cheap concentrating methods, could never be classed as ores

13.  Minerals

 An INorganically formed, naturally occurring homogeneous solid having a definite chemical composition and an orderly crystal structure

 Ore  Is a mineral deposit w/c can be ECONOMICALLY EXPLOITED to become a source or supply of a particular material

Gangue Mineral  All minerals having NO ECONOMIC VALUE to the recovery process under consideration

14. Unit Operations in Ore Dressing

 ComMINUtion 

 Sizing 

 Concentration 

 Dewatering 

 Auxiliary Operations

Comminution
 particle size reduction by breaking, crushing, or grinding of ore, rock, coal, or other materials
 It is a critical component in most mineral processing flow sheets and can serve several purposes
 Goals: LIBERATION and SEPARATION
 Done either wet or dry
 Consumes a lot of energy (>40% of total Mine/Mill consumption)

Sizing
 Segregation of Materials into products characterized by difference in size
 Screening and Classification

Concentration
 Separation of valuable minerals
 Based on the physical characteristics of minerals

Dewatering
 Solid/liquid separation by thickeners and filters

Auxiliary Operations
 Bins, conveyors, feeders, pumps, etc.

Process Flowsheet
 A diagrammatic representation showing the individual treatments, or unit operations in a process, and the order by which these are carried out

Process Integration and Flowsheet Analysis
Two factors are particularly significant in a Mineral Processing Circuit:
 Each ore is Unique
 Interrelation of various process operations (one unit affects the behavior of subsequent operations)

Basic Problems in Process-Flow Metallurgy
 Choosing possible products or suitable final products of operation
Source (raw material) > Product 1 Product 2 Product 3...

The ways in which these products should be produced
Source (raw material) > Route 1 Route 2 Route 3 . . . > Product 1

15.  Logical Framework for examining process selection problems:
 Raw mat’ls: pure or associated
 Valuable and unwanted Minerals
 Separability: Chemical or Physical
 Treatment: Single vs. multi-step process

To be able to select a suitable separation process route, a number of important characteristics of the ore should be defined

16. Mineral Characteristics
 The mineral phases which are present in the ore and their composition should be fully identified
 The volume and mass fraction of each minerals
 The grain sizes and size distribution
 Shape of the grains
 Orientation of the grains
 Distribution of the grains within the ore

17. Mineralogy

MINERAL CHARACTERISTIC
> PROPERTY UTILIZED
> TYPE OF OPERATION

Color and Luster
> Optical response
> Hand Sorting of ore or automatic device triggered by reflected light

Texture, Hardness
> Difference in the response to crushing, grinding, screening, classification
>Air separation of fibers like asbestos; Separation of diamonds

Radioactivity
>Gamma Ray Emission
>Automatic device triggered by scintillation counter

Specific Gravity and Mass
>Differential Displacement in a fluid due to difference in buoyant effect
>Gravity separation of heavies and Lights by HMS, Jig, Table, Spiral

Shape
>Frictional force developed in a stream flow
>Flowing film table separators

Ferromagnetism
>Magnetic
>Magnetic fields used to recover wanted mineral

Surface Conductivity
>Mobility of electrons on the Particle Surface
>High voltage separator

Surface Activity
>ADsorption of specific cations & anions to modify surface tensions
>Froth flotation, flocculation or agglomeration

FROM:

https://lookaside.fbsbx.com/file/INTRODUCTION%20prin%20of%20met%20rev.pdf?token=AWzm37HOha8q5SxoD0sEtD9p5yTIJRsw32qHLR7iGYHtmUKK23fJ8mbvKm6KJTKcW5jdporvQRd3FOdcaKAVJHg5y1vP5ht__vdYWQI5UpFfISrKLLyTvr5zAOyMiTHN3r2i2tLnarrQduWsRScpW59BqoAAXvix8E-5FxhmyJqYENR1mUZ1grR3kL4zVTFRGsjCMeBxZAqOxsUK1VQKmcgU

https://lookaside.fbsbx.com/file/mineral%20processing%20intro.pdf?token=AWxikDNyc_g5CbtFzc7nTszDjkM1eF0GC78cMOimI91vp-ugtWvf6SFp5QdZaKOqzOIhzl1e7Ko9ckIUKoxn7gnPhMk4LrSA91grfXomAk3saLGHLVZtpvBvQyf2zY29usltm5iuwotxSVdp0e0aaN6nb-OpHiBHcvmayKQRZ2oOjCUlsF4z2PwSiyLABQjsa4BC9XvFrlkAx-NJoIv7JpKX4bk8B76r6-oE_6Zm7fRMeA

#################################################################################
DISCLAIMER: please don't sue me, i just reformatted the slides for easier study, I don't mint money, this is for study notes, PEACE!

Mag-subscribe sa: I-post ang Mga Komento (Atom)