Extraction Metallurgy Ammar R. H. Alshemary Assistant Lecturer Department of Materials Engineering University of Kufa

2 Introduction:  The history of extraction metallurgy can be divided into two period –the ancient period, when a small number of metals was known, and the recent period, of about the last two centuries, when almost metals have become available commercially.  Many important metals are present in nature combined with sulfure as metal sulfides; these include cadmium, cobalt, copper, lead, nickel, zinc, and gold group.  Metals are associated with sulfides base metal ores.  The extraction of metals from their ores has been an essential factor in the creation and development level of civilization.  The first step in recovery metals from their ores is that of finding ore-bodies in which metal sulfides are present in a sufficient quantity, and at a sufficient concentration for mining to be economic.  The discovery of metals by depended on their being easily found, easily recognized as ores and easily reduced from these ores.  Extraction metallurgy is not confined to the production of a single metal from each ore.  Metals and sometimes non-metals, present in ores in very proportions may be concentrated into slags or dust which are sometimes of great value.

3 Some definitions of extraction metallurgy: Extraction Metallurgy: Extraction of metals from ore by chemical and mechanical methods. Ores : are rocks containing minerals that can be mined, processed and delivered to the market place. Minerals : are natural chemical compound and are natural products of various physic-chemical processes going on in the earth׳s crust. Ore deposit: rocks containing mineral of economic value in such amount that can be profitably exploited. Metals: an opaque crystalline material usually of high strength with good electrical and thermal conductivity, ductility and reflectivity. properties are related to the structure in which the positively charged ions are bonded through a field of free electrons which surrounds them forming a close- packed structures.

4 An ore must contain materials that are : 1)Valuable. 2)In concentration that can be profitably mined transported, milled, and processed. 3)Able to be extracted from waste rock by mineral processing techniques. The basic extraction of ore deposits fellows the steps: 1)Prospecting or exploration to find ores. 2)Conduct resource estimation to mathematically and grade of the deposit. 3)Conduct a feasibility study to determine the theoretical economic of the ore deposit. 4)Conduct a feasibility study to evaluate the financial viability. 5)Development to create access to an ore bodies and building of mine plant and equipment. 6)Reclamation to make land where a mine had been suitable for future use.

5 Ores types : 1)Oxides ores 2)Sulfide ores 3)Halides ores 4)Crystalline ores 1)Oxides ores : consider from important group and more presence in natural. For example the formation of iron oxides.(magnetite fe3o4, hematite fe2o3) 2)Sulfide ores: the major class of ore is probably the most common and is found on the sites at which it was deposited. This group associate with iron almost always present for ex. cadmium is found associated with zinc,iron with copper,copper, iron with nickel. 3)Halides ores : (salt rock) ex. sodium and magnesium chloride. 4)Crystalline ores : contain number different from metals, which have crystal contents for ex. chalcopyrite(CuFeS2).

6 The wining of ores : The first stage in the wining of ores is to find the: 1)Traditionally prospectors : were hardy enterprising mine seeking their fortunes with a clever eye for the tell-tale signs of valuable minerals. 2)modern prospecting : is organized by large mining companies by geologists and geophysicists who add skill sophisticated techniques. There are three techniques for modern prospecting: A- Electrical methods. B- Magnetic methods. C- Chemical methods. A- Electrical methods : involve the measurement of soil resistance or natural currents in soil surrounding. B- magnetic methods : include declination and inclination over wide areas from surface and geological formation thousands of feet below the surface. C- chemical methods : include the analyses of vegetation and sand from rivers to trace sources of minerals.

7 The physical and chemical properties of ores : Importance of properties which is depending on it extraction process for ores, is properties which distinguish ore every metal of other. There are two types of properties: 1- physical properties : include specific weight, colour, shape, size of particles and surface area. 2- Chemical properties : include process of separation for ores of metals, is depending on chemical interaction ores of metals. The evaluation of ore: 1- Exploration cost. 2- Wining cost. 3- Concentration cost. 4- Transportation cost. 5- Waste deposal cost. 6- Extraction cost. 7- Refining. 8- marketing cost.

8 Evaluation of ore deposit: 1- geological considerations: for exploitation project: A- fully knowledge of size,shape and location of ore deposit. B- Knowledge of grade(percent) for mineral in ore deposit. C- Knowledge of material that exists in ore deposit & possibility to recovery as occasion product like gold, silver or impurities. 2- Non-geological considerations: there are many factors: A- cost of mining :comprise cost of extraction of mineral from equipment and building. B- Cost of extraction processes: selection of methods of extraction depending on type of ore &impurities. C- Costs of deposal of waste far from work position. D- Cost of accessory materials for ore refining. E- Possibility of completely exploitation of production energy for mine. therefore increasing in exploitation will decreasing cost of mineral production. F- Energy: calculated from total free energy for reduction mineral component in ore. G- Handlers.

9 Sampling: for chemical and physical analysis for many reasons: 1- The control on the equipment or technological flow for processes. 2- The Classification of raw materials &quality control. 3- The Evaluation of price of raw materials according to quality. Processes for taking sample: Total ore(Ton) total sample(kg) lab. sample(gm) analysis sample(mg). Methods of fractionating of sample: Sampling (fractionating of sample): for chemical and physical Analyses of ores,should be taking A sample by the methods below: 1- Conning &quartering 2- Table sampling 3- Spinning riffling 4- Chute splitting 5- Scoop sampling

Fig: Methods of fractionating of sample 4 3 5