Lecture 5 - Metallic Materials I
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Transcript of Lecture 5 - Metallic Materials I
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MATERIALS ENGINEERING 10: ENGINEERING MATERIALS
Lecture 5: Metallic Materials I: Basic Concepts, Mineral Processing, & Metal Extraction
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OBJECTIVES
Describe important properties of metals
Explain the process used for extracting metals from ores
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THE BASIC MATERIAL CLASSIFICATIONS
COMPOSITES ELECTRONIC
MATERIALS
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METALS
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METALS
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METALS Good thermal and electrical
conductors
Strong yet deformable
Not transparent
Lustrous
Do not easily break
Malleable
Ductile
High-density
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Ductility of Metals
Deformation under tensile stress
cup and cone failure
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Malleability of Metals Deformation under compressive stress
A gold nugget of 5 mm in diameter can be expanded through hammering into a gold foil of about 0.5 square meter.
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Toughness
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Electrical Conductivity of Metals
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Thermal Conductivity of Metals
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So where do metals come from?
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Short answer: from the EARTH.
Long answer: by mining raw ore from the earth and converting this to raw metal, which is then processed to refined metal.
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Metal Sources
NATURAL RECYCLED
VALUABLE
MINERAL
GANGUE
• Valuable minerals – mixture of minerals , one or more of which can be economically exploited to become a source or supply of a particular metal • Gangue – minerals of no economic value
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MAGNETITE
(Fe3O4) HEMATITE
(Fe2O3)
LIMONITE
(Fe2O3•H2
O)
CHALCOPYRITE
(CuFeS2)
BORNITE
(FeS•2CU2S•
CuS)
BAUXITE
(Al2O3•H2
O)
GALENA
(PbS)
ARGENTITE
(Ag2S)
IRON COPPER
ALUMINUM LEAD SILVER
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Thinking Part
Think of some advantages of using recycled metal over raw ore in metal production.
For all these advantages, why do you think recycled metal is secondary to raw ore?
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Thinking Part
Advantages:
involves fewer and simpler processing operations
requires less total energy during recovery
produces less pollution during the process
Disadvantage: difficulty in collection as well as sorting of scrap
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Metal
Energy Expended
on Production
from Ore (primary)
Energy Expended
on Recovery from Scrap (secondary)
Net Energy Savings on Recycling
Magnesium 372 10 362
Aluminum 253 13 340
Nickel 150 16 134
Copper 116 19 97
Zinc 68 19 49
Steel 33 14 19
Lead 28 10 18
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Of course, we cannot use this ore in its raw form.
They have to undergo the process of MINERAL PROCESSING.
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MINERAL PROCESSING
COMMINUTION
SIZING
CONCENTRATION
DEWATERING
• liberation of valuable minerals from the ores by crushing and grinding, and their separation by physical methods
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1. Comminution Crushing of ore to smaller sizes necessary for mechanical
separation and metallurgical treatment
Why?
to increase the surface area available for chemical reaction
CRUSHING GRINDING
Crushing – blocks to coarse (Jaw Crushers) Grinding – coarse to fine (Roll Crushers)
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2. Sizing Separation of fractions into component sizes
SCREENING/SIEVING CLASSIFICATION
usually done in between comminution steps to ensure particle size
Separation of materials which depends on the settling velocity of
particles in a fluid (1mm to 50 microns)
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3. Concentration Separation and collection of valuable minerals
in bulk. GRAVITY SEPARATOR
FLOTATION
ELECTROSTATIC
MAGNETIC
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3. Concentration Gravity Concentration
Collection of valuable minerals wherein specific gravity and in some cases, sizes are the basis for effecting concentration (concentrate, fine particles, gangue tailings)
Electrostatic Concentration
Separation carried out by utilizing forces acting on charged or polarized particles in an electric field
Flotation
Separation is accomplished as the mineral-laden bubbles rise to the surface and leave behind minerals or ore particles which have not responded to the treatment
Magnetic Separation
Magnetic materials are separated from the gangue due to the action of the applied magnetic field on the drum
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4. Dewatering
Removal of water from solids
Objectives:
• Decrease pulp weight to reduce handling and shipping cost • Adjust the characteristics of the process streams so that they are suitable for subsequent treatments • Necessary to be able to recover and recycle water within the plant and prevent contamination of freshwater resources
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4. Dewatering
THICKENING FILTERING
Thickening Allows a dilute suspension of fine
solids in a liquid to settle in a
tank, until a clear liquid layer is at
the top of thicker mud layer
Filtering Done by removing solid particles
from the liquid by passing the
fluid through a filtering medium
on which the solids build up
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Once we have our ore refined to the highest possible purity, we will now extract the metal from the ore.
Most of the time, ore = chemical compound.
Therefore, we NEED a CHEMICAL process to extract our metal!
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METAL EXTRACTION
PYROMETALLURGY
HYDROMETALLURGY
ELECTROMETALLURGY
• chemical processing of a concentrate
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Pyrometallurgy
High-temperature, non-aqueous reactions
Uses thermodynamic data to predict whether a reaction proceeds
Same data is used to predict effect of changing temperature
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Pyrometallurgy
separation melting smelting
reducing a metallic ore to a crude metal
Matte solutions of various sulfides (usually of copper, iron and nickel)
Slag less dense (non-valuable constituent)
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Hydrometallurgy
Production of metallic materials/ compounds from ores/scrap at a specific temperature range: (T < 300°C, P< 300 psi)
Desired metals are dissolved into aqueous medium (leachant), purified then recovered.
Leaching
Solution Purification
and Concentration
Metal Recovery/ Winning
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1. Leaching
Use of an aqueous solvent/ lixiviant in ore dissolution
a. Concentration Leaching – desired metal is dissolved (e.g. dissolution of gold)
4Au + 8KCN + O2 + 2H2O 4KAu(CN)2 + 4KOH
b. Separation Leaching – undesirable mineral constituent is removed or dissolved; residue is the valuable product (e.g. leaching of ilmenite)
FeTiO3 + 2HCl TiO2 + FeCl2(aq) + H2O
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2. Solution Purification and Concentration removal of undesirable constituents in the
leach liquor (pregnant solution) and pre-concentration of the metal in the solution
Methods:
1. Ion Exchange – uses synthetic polymer resins designed to exchange ions for ions in solution
2. Solvent Extraction – a distributive process wherein the valuable metal is allowed to partition itself between two immiscible phases
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3. Metal Winning Final recovery of metal
i. Precipitation – the formation from the solution of a solid product as the result of dilution or addition of a reagent to the solution
ii. Electrolytic Deposition – uses electrons for the reduction of metal ions
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Electrometallurgy Utilizes electrons for reduction of metal ions
Uses reactivity series for:
Metal recovery from solution – ELECTROWINNING
Metal purification – ELECTROREFINING
Application of metallic coating - ELECTROPLATING
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Electrowinning electrolytic process in which cathodic
reduction is used to recover the sought metal from the electrolyte derived from a leaching process.
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Electrorefining involves dissolution of the impure metal
(anode) producing metal ions in solution. Metal ions in solution are conducted through an electrolyte and recombine with electrons in the cathode to produce a purified metal.
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Electroplating process that uses
electric current to reduce dissolved metal cations so that they form a coherent metal coating on an electrode.
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Thank you for listening!