Extractive metallurgy: 2 Metallurgical reaction processes
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| Format: | Buch |
| Sprache: | English |
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London
ISTE
2011
Hoboken, NJ Wiley 2011 |
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | XVI, 347 S. graph. Darst. |
| ISBN: | 9781848212879 |
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Datensatz im Suchindex
| _version_ | 1804148544458719232 |
|---|---|
| adam_text | Titel: Bd. 2. Extractive metallurgy. Metallurgical reaction processes
Autor: Vignes, Alain
Jahr: 2011
Table of Contents
Preface
XI
Chapter 1. Hydrometallurgical Extraction Processes.............. 1
1.1. Overview of hydrometallurgical processes................. 1
1.2. Leaching processes............................... 2
1.2.1. Basic features................................ 2
1.2.2. Leaching of oxides with acid-base reactions.............. 5
1.2.3. Leaching of sulfides............................ 12
1.2.4. Leaching of metals............................. 37
1.3. Precipitation processes............................. 39
1.3.1. Precipitation of hydroxides and oxides................. 40
1.3.2. Precipitation of sulfides.......................... 48
1.3.3. Production of Cu, Ni and Co metallic powders from salt
solutions by reduction with hydrogen...................... 49
1.3.4. Cementation................................. 52
1.4. Solvent extraction................................ 55
1.4.1. Extractants.................................. 55
1.4.2. Extraction and stripping isotherms and extractant
selectivity...................................... 57
1.4.3. Solvent extraction operations in copper hydrometallurgic
treatments...................................... 60
1.4.4. Cobalt-nickel separation from various leach liquors by
solvent extraction.................................. 61
1.4.5. Iron extraction from a sulfuric Fe-Zn solution............. 62
1.4.6. Extraction of gold from hydrochloric solutions............ 62
1.4.7. Extraction of gallium from Bayer process leach solutions...... 62
1.5. Hydrometallurgical processing routes of ores, concentrates and
residue (flowsheets)................................. 62
vi Extractive Metallurgy 2
1.5.1. The Bayer process: bauxite processing................. 63
1.5.2. Hydrometallurgical processing routes of zinc ores and
electric arc furnace dusts............................. 67
1.5.3. Hydrometallurgical processing routes of copper ores
and mattes...................................... 73
1.5.4. Processing of nickel laterites, sulfide concentrates
and mattes...................................... 75
1.6. Bibliography................................... 81
Chapter 2. Electrometallurgical Extraction Processes............. 87
2.1. Overview of electrometallurgical processes................. 87
2.2. Electrolysis - bases............................... 88
2.2.1. The electrolytic cell............................ 88
2.2.2. Faraday s law................................ 89
2.2.3. The electromotive force (EMF)..................... 90
2.2.4. Electrical energy consumption...................... 92
2.2.5. Decomposition potential of a salt.................... 92
2.2.6. Electrorefining............................... 94
2.2.7. Configurations of industrial cells and cell lines............ 95
2.3. Aqueous electrolysis: bases.......................... 98
2.3.1. Electrolytic water decomposition.................... 98
2.3.2. Aqueous salt electrolysis......................... 99
2.3.3. Metal deposit and hydrogen production................. 101
2.3.4. Electrodeposition of metals-deposit morphologies......... 102
2.4. Electrowinning of copper............................ 103
2.4.1. Copper chloride electrolysis....................... 103
2.4.2. Copper sulfate electrolysis........................ 104
2.4.3. Electrolytic copper and blister copper electrorefining........ 106
2.4.4. Electrorefining of copper matte..................... 107
2.5. Electrowinning of nickel............................ 108
2.5.1. Nickel chloride electrolysis........................ 108
2.5.2. Electrorefining of nickel.......................... 108
2.5.3. Electrorefining of nickel matte...................... 109
2.6. Electrowinning of zinc............................. Ill
2.6.1. Zinc sulfate electrolysis.......................... Ill
2.6.2. Ammonium chloride zinc electrolysis.................. 113
2.6.3. Sodium zincate electrolysis........................ 114
2.7. Electrorefining of lead............................. 114
2.8. Electrorefining of tin.............................. 115
2.9. Cobalt electrowinning.............................. 115
2.10. Bibliography.................................. 115
Table of Contents vii
Chapter 3. Halide Extraction Processes...................... 117
3.1. Overview of the halide extraction processes................ 117
3.2. Chlorination processes............................. 118
3.2.1. Thermodynamic data............................ 119
3.2.2. Mechanisms and kinetics......................... 124
3.2.3. Carbochlorination of ores......................... 130
3.3. Reduction of halides.............................. 132
3.3.1. Hydrogen reduction............................ 132
3.3.2. Metallothermic reduction......................... 133
3.4. Bibliography................................... 137
Chapter 4. Reduction of Metal Oxides....................... 139
4.1. Introduction.................................... 139
4.1.1. Overview of the oxide reduction processes............... 139
4.1.2. Thermodynamics: basic considerations................. 140
4.1.3. Mechanisms and kinetics: basic considerations............ 145
4.2. Solid state oxide reduction by a gaseous reducing agent......... 148
4.2.1. Industrial operations............................ 148
4.2.2. Thermodynamics.............................. 149
4.2.3. Mechanism and kinetics.......................... 160
4.2.4. Reduction of iron oxides.......................... 161
4.2.5. Reducibility of iron ores.......................... 163
4.2.6. Reduction of chromite........................... 165
4.2.7. Reduction of manganese oxides..................... 166
4.2.8. Reduction of ilmenite........................... 166
4.2.9. Reduction of tungsten and molybdenum oxides............ 166
4.3. Solid-state carbothermic reduction...................... 168
4.3.1. Industrial operations............................ 168
4.3.2. Mechanisms................................. 169
4.3.3. Direct reduction: thermodynamics and kinetics............ 171
4.3.4. Reduction of chromium oxide and chromite.............. 174
4.3.5. Reduction of manganese oxide and manganese ore.......... 176
4.3.6. Indirect reduction: thermodynamics and kinetics........... 177
4.3.7. Reduction of the iron oxides....................... 180
4.3.8. Reduction of zinc ferrite.......................... 181
4.3.9. Carburizing reduction by methane-containing gas.......... 182
4.4. Carbothermic smelting reduction....................... 183
4.4.1. Industrial operations............................ 183
4.4.2. Thermodynamics.............................. 183
4.4.3. Mechanisms................................. 184
4.4.4. Reduction of iron oxide.......................... 187
4.4.5. Reduction of chromium oxide...................... 189
viii Extractive Metallurgy 2
4.4.6. Reduction of manganese oxide...................... 192
4.4.7. Reduction of manganese ore....................... 193
4.4.8. Production of silicomanganese alloy.................. 194
4.5. Smelting reduction by slag-metal reactions................. 195
4.5.1. Reaction systems.............................. 195
4.5.2. Thermodynamics and kinetics...................... 195
4.5.3. Reduction of iron oxides in reaction system II............. 197
4.5.4. Reduction of iron oxides in reaction system III............ 198
4.5.5. Reduction of chromium oxide...................... 200
4.5.6. Reduction of silica............................. 201
4.5.7. Silicomanganese production....................... 203
4.6. Carbothermic reduction of silica and alumina............... 203
4.6.1. Conversion of silica into silicon carbide................ 203
4.6.2. Reduction of silica into silicon...................... 205
4.6.3. Reduction of alumina........................... 208
4.7. Metallothermic reductions........................... 212
4.7.1. Silicothermic ferroalloys production.................. 212
4.7.2. Silicothermic reduction of magnesia MgO............... 213
4.7.3. Calciothermic reduction of titanium oxide............... 215
4.7.4. Aluminothermic reduction........................ 216
4.8. Bibliography................................... 216
Chapter 5. Oxygen Steelmaking........................... 221
5.1. Overview of steel converting and refining operations........... 221
5.2. Converting and refining reactions....................... 222
5.2.1. Oxidation of hot metal elements by gaseous oxygen......... 222
5.2.2. Metal-slag reactions............................ 223
5.3. Oxidation of hot metal elements by gaseous oxygen........... 226
5.3.1. Basic considerations............................ 226
5.3.2. Gaseous oxidation of pure iron...................... 228
5.3.3. Oxidation of a Fe-C alloy......................... 229
5.3.4. Oxidation of Fe-C-Si alloys........................ 230
5.3.5. Oxidation processes in hot metal converting industrial
operations...................................... 231
5.4. Slag-metal reactions............................. 232
5.4.1. Overview................................... 232
5.4.2. Oxidation kinetics of the hot metal elements.............. 232
5.4.3. Hot metal desiliconizing and manganese metal-slag partition. . . . 234
5.4.4. Decarburization............................... 235
5.4.5. Dephosphorization............................. 237
5.4.6. Thermodynamic modeling of a hot metal-converting
operation....................................... 243
Table of Contents ix
5.5. Stainless steel making.............................. 245
5.6. Ultra-low carbon steel making......................... 249
5.7. Bibliography................................... 252
Chapter 6. Sulfide Extraction Processes...................... 255
6.1. Introduction.................................... 255
6.1.1. Overview of industrial operations.................... 255
6.1.2. Thermodynamic considerations..................... 256
6.2. Oxidation of sulfides (in the solid state)................... 258
6.2.1. Thermodynamics.............................. 258
6.2.2. Mechanism and kinetics.......................... 265
6.3. Matte oxidation by gaseous oxygen..................... 269
6.3.1. Copper matte................................ 269
6.3.2. Iron matte.................................. 272
6.3.3. Fe-Cu-S matte................................ 274
6.4. Reactions occurring in smelting and converting operations....... 274
6.4.1. Mechanisms................................. 274
6.4.2. FeS matte/magnetite reactions...................... 275
6.4.3. (Fe-Cu-S)-matte/copper oxide and matte-slag reactions....... 276
6.4.4. (Fe-Ni-S)-matte/nickel oxide and matte-slag reactions........ 279
6.4.5. Typical data on Fe-Cu-S and Fe-Ni-S converting matte
compositions.................................... 279
6.4.6. Thermodynamic modeling of primary converting of a matte .... 282
6.5. Smelting reduction of a roasted concentrate and primary
converting....................................... 284
6.6. Secondary converting of Cu2S, Ni3S2 and PbS mattes........... 285
6.6.1. Copper matte................................ 286
6.6.2. Nickel matte................................. 289
6.6.3. Lead matte.................................. 291
6.7. Bibliography................................... 291
Chapter 7. Metal Refining Processes........................ 295
7.1. Introduction.................................... 295
7.2. Steel refining/secondary steelmaking.................... 296
7.2.1. Introduction................................. 296
7.2.2. Secondary steelmaking stations..................... 296
7.2.3. Steel deoxidation and inclusion control................. 298
7.2.4. Desulfurization of hot metal and steel.................. 300
7.2.5. Dehydrogenization and denitrogenization............... 307
7.3. Aluminum refining............................... 310
7.3.1. Primary aluminum refining........................ 310
7.3.2. Recycled aluminum refining....................... 312
x Extractive Metallurgy 2
7.4. Copper refining................................. 313
7.5. Lead refining................................... 315
7.5.1. Decoppering................................. 315
7.5.2. Removal of arsenic, antimony and tin.................. 317
7.5.3. Removal of bismuth............................ 317
7.5.4. Removal of silver (Parkes process)................... 317
7.6. Tin refining.................................... 318
7.7. Zinc refining................................... 318
7.8. Titanium and zirconium refining....................... 319
7.9. Nickel refining.................................. 319
7.9.1. Carbonylation (transport reaction).................... 320
7.9.2. Separation by distillation of carbonyl compounds........... 321
7.9.3. Precipitation of nickel........................... 321
7.10. Bibliography.................................. 321
List of Symbols...................................... 325
Index............................................ 337
Summary of Other Volumes.............................. 349
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| title_full_unstemmed | Extractive metallurgy 2 Metallurgical reaction processes Alain Vignes |
| title_short | Extractive metallurgy |
| title_sort | extractive metallurgy metallurgical reaction processes |
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