Physical Chemistry of Metallurgical Processes

Foreword to the First Edition
Preface to the First Edition
Preface to Second Edition
Contents
Abbreviations
List of Figures
List of Tables
Chapter 1: Introduction
	1.1 Thermodynamic Quantities and Their Interrelationships
		1.1.1 General Thermodynamics
		1.1.2 Solution Thermodynamics
	Further Reading
Chapter 2: Roasting of Sulfide Minerals
	2.1 Methods of Roasting
	2.2 Objectives
	2.3 Chemistry of Roasting
	2.4 Thermodynamics of Roasting
	2.5 Kinetics of Roasting
	2.6 Predominance Area Diagrams as a Useful Guide in Feed Preparation
	2.7 Problems
	References
Chapter 3: Sulfide Smelting
	3.1 Matte Smelting of Chalcopyrite
		3.1.1 Suspension Smelting
			3.1.1.1 Flash Smelting
			3.1.1.2 Cyclone Smelting
		3.1.2 Bath Smelting
			3.1.2.1 Submerged Tuyere Smelting
			3.1.2.2 Ausmelt/Isasmelt-Top-Submerged Lancing (TSL) Technology
	3.2 Converting of Copper Matte
		3.2.1 Pierce-Smith Converting
			3.2.1.1 Stages of the Converting Process
			3.2.1.2 Physical Chemistry of Matte Converting
	3.3 Continuous Converting
		3.3.1 Noranda Continuous Converting Process
		3.3.2 Kennecott-Outotec Flash Converting Process
		3.3.3 Mitsubishi Continuous Converting Process
	3.4 Direct Copper Extraction from Concentrate
		3.4.1 Outotec Blister Flash Smelting Process
		3.4.2 Mitsubishi Process
	3.5 Matte Smelting of Galena
	3.6 Smelting of Pentlandite (Nickel-Copper-Iron Sulfide)
		3.6.1 Matte Smelting of Pentlandite
		3.6.2 Converting of Nickel Matte
			3.6.2.1 Physicochemical Aspects of Direct Conversion of Molten Nickel Sulfide into Nickel
	3.7 Rate of Smelting and Converting Processes
	3.8 Problems
	References
Chapter 4: Metallurgical Slag
	4.1 Structure of Oxides
		4.1.1 Classification of Oxides
	4.2 Structure of Slag
	4.3 Properties of Slag
		4.3.1 Oxidizing Power of Slag
		4.3.2 Basicity of Slag
		4.3.3 Sulfide Capacity of Slag
		4.3.4 Electrical and Thermal Conductivity
		4.3.5 Viscosity
		4.3.6 Surface Tension
		4.3.7 Diffusivity
	4.4 Constitution of Metallurgical Slags
		4.4.1 State of Oxidation of Slag
	4.5 Slag Theories
		4.5.1 Ionic Theories
			4.5.1.1 Temkin Theory
			4.5.1.2 Flood Theory
			4.5.1.3 Masson theory
		4.5.2 Molecular Theory
	4.6 Problems
	References
Chapter 5: Reduction of Oxides and Reduction Smelting
	5.1 Reduction Methods
	5.2 Thermodynamics of Reduction of Oxides
		5.2.1 Metallothermic Reduction
		5.2.2 Thermal Decomposition
		5.2.3 Reduction with Carbon Monoxide in the Presence and Absence of Carbon
		5.2.4 Reduction with Hydrogen
	5.3 Kinetics of Reduction of Oxides
		5.3.1 Gnistling and Brounshtein Simplified Model
		5.3.2 Valensi Model
		5.3.3 Other Mathematical Models
	5.4 Commercial Processes
		5.4.1 Production of Iron
			5.4.1.1 Recent Trends in Ironmaking
		5.4.2 Production of Zinc
		5.4.3 Production of Tungsten and Molybdenum
	5.5 Problems
	References
Chapter 6: Interfacial Phenomena
	6.1 Precipitation
	6.2 Nucleation of Gas Bubbles in a Liquid Metal
		6.2.1 Role of Interfaces in Slag-Metal Reactions
	6.3 Emulsion and Foam
	6.4 Froth Flotation
	6.5 Other Applications
	6.6 Problems
	References
Chapter 7: Steelmaking
	7.1 Steelmaking Processes
		7.1.1 Bessemer Process
		7.1.2 Open-Hearth Process
		7.1.3 Electric Arc Furnace (EAF) Process
		7.1.4 Top-Blown Basic Oxygen Converter Process
		7.1.5 Rotating Oxygen-Blown Converter Process
		7.1.6 Bottom-Blown Oxygen Converter Process
		7.1.7 Hybrid/Bath-Agitated/Combined-Blown Process
	7.2 Physicochemical Principles
		7.2.1 Sulfur Reactions
		7.2.2 Phosphorus Reactions
		7.2.3 Silicon Reactions
		7.2.4 Manganese Reactions
		7.2.5 Carbon Reactions
		7.2.6 Kinetics of Slag-Metal Reactions
	7.3 Pre-treatment of Hot Metal
		7.3.1 External Desiliconization
		7.3.2 External Desulfurization
		7.3.3 External Dephosphorization
		7.3.4 Simultaneous Removal of Sulfur and Phosphorus
	7.4 Chemistry of Refining
		7.4.1 Important Chemical Reactions in Steelmaking
			7.4.1.1 Top-Blown Basic Oxygen Converter Process
			7.4.1.2 Bottom-Blown Oxygen Converter Process
			7.4.1.3 Hybrid/Bath-Agitated/Combined-Blown Process
			7.4.1.4 Rotating Oxygen-Blown Converter Process
		7.4.2 Electric Arc Furnace (EAF) Process
		7.4.3 Open-Hearth Process
		7.4.4 Bessemer Process
	7.5 Problems
	References
Chapter 8: Secondary Steelmaking
	8.1 Inert Gas Purging (IGP)
	8.2 Ladle Furnace (LF)
	8.3 Deoxidation
		8.3.1 Choice of Deoxidizers
		8.3.2 Complex Deoxidizers
		8.3.3 Vacuum Deoxidation
		8.3.4 Deoxidation Practice
		8.3.5 Removal of Deoxidation Products
	8.4 Stainless Steelmaking
		8.4.1 Physicochemical Principles
		8.4.2 Stainless Steelmaking Processes
			8.4.2.1 AOD Process
			8.4.2.2 VOD Process
			8.4.2.3 Direct Stainless Steelmaking Processes
	8.5 Injection Metallurgy (IM)
	8.6 Refining with Synthetic Slag
	8.7 Vacuum Degassing
		8.7.1 Nitrogen in Iron and Steel
		8.7.2 Hydrogen in Iron and Steel
		8.7.3 Vacuum Treatment of Steel
			8.7.3.1 Ladle Degassing
			8.7.3.2 Stream Degassing
			8.7.3.3 Circulation Degassing
	8.8 Problems
	References
Chapter 9: Role of Halides in Extraction of Metals
	9.1 Preparation of Halides
		9.1.1 Complex Fluoride Processes
			9.1.1.1 Fluorination of Beryl
			9.1.1.2 Fluorination of Zircon
		9.1.2 Halogenation of Oxides
			9.1.2.1 Hydrofluorination
			9.1.2.2 Chlorination
		9.1.3 Halogenation of Ferro-Alloys
			9.1.3.1 Fluorination of Ferro-Niobium
			9.1.3.2 Chlorination of Ferro-Niobium and Ferro-Vanadium
		9.1.4 Crystallization from Aqueous Solution
			9.1.4.1 Dehydration of Carnallite
			9.1.4.2 Dehydration of Bischofite
	9.2 Purification of Chlorides
		9.2.1 Purification of Titanium Tetrachloride
		9.2.2 Purification of Niobium Pentachloride
		9.2.3 Purification of Vanadium Tetrachloride
	9.3 Metal Production
		9.3.1 Metallothermic Reduction
			9.3.1.1 Reduction of Uranium Tetrafluoride
			9.3.1.2 Reduction of Titanium Tetrachloride
			9.3.1.3 Reduction of Zirconium Tetrachoride
			9.3.1.4 Reduction of Beryllium Fluoride
			9.3.1.5 Reduction of Chlorides of Niobium/Tantalum and Vanadium
			9.3.1.6 Reduction of Potassium Heptafluoroniobate/Tantalate
		9.3.2 Fused Salt Electrolytic Process
	9.4 Purification
		9.4.1 Disproportionate Process
		9.4.2 Iodide Process
	9.5 Problems
	References
Chapter 10: Refining
	10.1 Principle
	10.2 Methods of Refining
		10.2.1 Fire Refining
			10.2.1.1 Refining of Pig Iron
			10.2.1.2 Refining of Copper
			10.2.1.3 Refining of Lead Bullion
		10.2.2 Metal-Metal Refining
			10.2.2.1 Liquation
		10.2.3 Metal-Gas Refining
			10.2.3.1 Distillation
			10.2.3.2 Pyrovacuum Treatment
			10.2.3.3 Carbonyl Process
		10.2.4 Miscellaneous Group
	10.3 Ultra-Purification
		10.3.1 Zone Refining
		10.3.2 Electrotransport
		10.3.3 Iodide Decomposition
	10.4 Refining Along with Melting and Consolidation
	10.5 Problems
	References
Chapter 11: Hydrometallurgy
	11.1 Leaching
		11.1.1 Leaching Methods
			11.1.1.1 In Situ Leaching
			11.1.1.2 Heap Leaching
			11.1.1.3 Percolation Leaching
			11.1.1.4 Agitation Leaching
			11.1.1.5 Pressure Leaching
			11.1.1.6 Bacterial Leaching
	11.2 Breakdown of Refractory Minerals
		11.2.1 Concentrated Sulfuric Acid Breakdown
		11.2.2 Concentrated Alkali Breakdown
	11.3 Physicochemical Aspects of Leaching
		11.3.1 Thermodynamics of Aqueous Solutions
		11.3.2 Stability Limit of Water
		11.3.3 Potential-pH Diagrams
		11.3.4 Electrochemical Phenomenon in Leaching
		11.3.5 Kinetics of Leaching
			11.3.5.1 Kinetics of Leaching of Gold Ore in Cyanide Solution
			11.3.5.2 Kinetics of Leaching of Copper in Cyanide Solution
			11.3.5.3 Kinetics of Leaching of Pitchblende in Sodium Carbonate Solution
			11.3.5.4 Kinetics of Leaching of Gibbsite in Sodium Hydroxide Solution
			11.3.5.5 Kinetics of Leaching of Cuprite in Sulfuric Acid
			11.3.5.6 Kinetics of Leaching of Scheelite in Sodium Carbonate Solution
			11.3.5.7 Kinetics of Leaching of Sulfides
	11.4 Treatment of Leach Liquor
		11.4.1 Chemical Precipitation
		11.4.2 Fractional Crystallization
		11.4.3 Activated Carbon
		11.4.4 Ion Exchange
			11.4.4.1 Ion Exchange Resins
			11.4.4.2 Principle
			11.4.4.3 Kinetics of Exchange Reaction
			11.4.4.4 Ion Exchange Process
			11.4.4.5 Applications in Metallurgy
		11.4.5 Solvent Extraction
			11.4.5.1 Basic Principles and Process
			11.4.5.2 Mechanism
			11.4.5.3 Desirable Characteristics of a Solvent and Various Solvents
			11.4.5.4 Factors Influencing Extraction
			11.4.5.5 Kinetics of Solvent Extraction
			11.4.5.6 Applications in Metallurgy
	11.5 Recovery of Metals from Leach Liquor
		11.5.1 Precipitation of Metal Sulfides
			11.5.1.1 Kinetics of Precipitation of Sulfides
			11.5.1.2 Sulfide Precipitation Practice
		11.5.2 Cementation
			11.5.2.1 Kinetics of Cementation
			11.5.2.2 Cementation Practice
		11.5.3 Gaseous Reduction
			11.5.3.1 Kinetics of Precipitation by Hydrogen
			11.5.3.2 Hydrogen Reduction Practice
	11.6 Problems
	References
Chapter 12: Electrometallurgy
	12.1 Principle
		12.1.1 Cell Potential
		12.1.2 Discharge Potential
		12.1.3 Current and Energy Efficiency
	12.2 Applications
		12.2.1 Electrowinning
			12.2.1.1 Electrowinning from Aqueous Electrolytes
			12.2.1.2 Electrowinning from Fused Salt Electrolytes
		12.2.2 Electrorefining
			12.2.2.1 Electrorefining from Aqueous Electrolytes
			12.2.2.2 Electrorefining from Fused Salt Electrolytes
	12.3 Problems
	References
Appendixes
	A.1: Flow Sheet for Extraction of Copper from Chalcopyrite
	A.2: Flow Sheet for Extraction of Lead from Galena
	A.3a: Flow Sheet for Extraction of Nickel from Pentlandite Via Pyrometallurgical Route
	A.3b: Flow Sheet for Extraction of Nickel from Pentlandite Via Hydrometallurgical Route
	A.4a: Flow Sheet for Extraction of Zinc from Sphalerite Via Pyrometallurgical Route
	A.4b: Flow Sheet for Extraction of Zinc from Sphalerite Via Hydrometallurgical Route
	A.5: Flow Sheet for Extraction of Tungsten from Scheelite/Wulframite
	A.6: Flow Sheet for Extraction of Beryllium from Beryl
	A.7: Flow Sheet for Extraction of Uranium from Pitchblende
	A.8: Flow Sheet for Extraction of Thorium from Monazite
	A.9: Flow Sheet for Extraction of Titanium from Rutile
	A.10: Flow Sheet for Extraction of Zirconium from Zircon Sand
	A.11: Flow Sheet for Extraction of Aluminum from Bauxite
	A.12: Flow Sheet for Extraction of Magnesium from Sea Water
	Appendix: B - Recommended Values of Physical Constants
	Appendix: C - SI Units and Conversion Factors
Index