Extraction Metallurgy

This book deals with the processes, operations, technologies and processing routes of extractive metallurgy, extraction of metals from ores, concentrates (enriched ores), scraps and other sources and their refining to liquid metals before casting or to solid metals. The book shows the recalling steps of the progress of metallurgy. These steps are identical to human progress of different ages like the copper age, the bronze age, the iron age and the silicon age. This book also gives detail about extracting copper from its ore dates back to the middle of the fifth millennium before our age and extracting iron from its ore dates back from the beginning of the second millennium before our age.

Paulene Fincher holds Ph.D. in Materials Science and Engineering from EngineeringCollege, Alagoas. She is an Associate Lecturer at Community College, Rio Cuarto. She is actively engaged in the researches focused onphysical extraction operations, steel making operations, hydrometallurgical operations, extractive processing routes, sulfide and matte smelting and converting operations, biomaterials, metallurgy and ceramics. Fincher has been the recipient of two awards for her research work in the field of crystallography of polymers. She has authored and edited numerous articles, journal papers and book in the field of materials science and engineering.

Preface VII
1. Physical Extraction Operations 1
1.1 Introduction 1
1.2 Solid-solid and Solid-Fluid Separation Operations 2
1.3 Separation Operations of the Components of a Fluid Phase 18
2. Hydrometallurgical Operations 24
2.1 Introduction 24
2.2 Leaching and Percipitation Operations 24
2.3 Reactor Models Based on Particle Residence Time Distribution Functions 45
2.4 Reactor Models Based on the Population Balance Equation Model 52
2.5 Solvent Extraction Operation 53
3. Gas-solid and Solid-solid Reactors and Particle Conversion Operations 56
3.1 Introduction 56
3.2 Fluid Dynamics 57
3.3 Hydrodynamic Regime 67
3.4 Fixed-Bed Reactors 72
3.5 Fluidized bed Reactor 73
3.6 Gasification 75
3.7 Rotary Hearth Furnace (RHF) 78
3.8 Rotary kiln 78
3.9 Multiple Hearth Furnace 83
4. Blast Furnaces 84
4.1 Introduction 84
4.2 History 86
4.3 Evolution of Blast Furnace Dimension 91
4.4 Blast Furnace Size 91
4.5 Process Description 92
4.6 Iron Blast Furnaces 92
4.7 Ferromangan.ese 100
4.8 Zinc Blast Furnaces (Imperial Smelting Furnaces) 100
4.9 Lead Blast Furnaces 108
5. Smelting Reduction Operations 110
5.1 Introduction 110
5.2 Smelting Reduction Operations 110
5.3 Smelt Reduction for Iron and Steel Sector 115
5.4 Lead Smelting 124
5.5 Zinc Smelting 126
5.6 Magnetherm Process 127
6. Steelmaking Operations 133
6.1 Introduction 133
6.2 The Modern Steel Production Process 134
6.3 Primary Steelmaking 135
6.4 Secondary Steelmaking 153
6.5 HIsarna Ironmaking Process 159
6.6 Stainless Steel Making Operations 163
7. Sulfide and Matte Smelting and Converting Operations 170
7.1 Introduction 170
7.2 Sulfidic Ore Processing 171
Bibliography 184
Index 186