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METALLURGICAL ENGINEERING - Coggle Diagram
METALLURGICAL ENGINEERING
:timer_clock: History
Ages in History
Present Age
Iron Age
Bronze
Age
Stone Age
Metals used throughout history
Gold
Copper
Silver
Lead
Iron
Mercury
Tin
"The art and science of extracting and refining metals from primary and secondary sources to characterize, process, and fabricate for application and use at a profit with utmost consideration of the environment"
Extractive Metallurgy
:ocean: Hydrometallurgy
Steps
Communition
control fineness of feed material
Roasting
heating of ore in excess air
Leaching
to dissolve the valuable mineral into leach liquor
Solid-liquid separation
separate leach liquor from unwanted mineral
Metal recovery
final extraction of the metal from solution
Waste treatment
treatment of liquor to be recycled in the operation
Leaching
Lixivants
Acids
Bases
Aqueous Salts
Water
liquid or reagents used to selectively extract/dissolve desired metals
Leaching Methods
Dump Leaching
Heap Leaching
In-Situ Leaching
Vat Leaching
Agitation Leaching
Pressure Leaching
involves selective dissolution of valuable metal in a suitable reagent or lixiviant
Solution Purification and Concentration
Pregnant Solution
Enriched Solution
Barren Solution
Ion Exchange
Eluant
Eluate
Adsorption Process
Carbon-in-Leach
Carbon-in-pulp
Solvent Extraction
treatment of ores by dissolution in aqueous solutions
:fire: Pyrometallurgy
Refractories
Alumina (Al2O3)
Silica (SiO2)
Dolomite (CaMg(CO3)2)
Magnesia (MgO)
non-metallic materials that have properties that allow them to be exposed in extremely high temperatures
Smelting
separation by mellting
Converting
refining and purifying of metal after smelting
Phases
Dross
solid impurities
Slag
molten oxide solution
Speiss
unwanted arsenide solution
Matte
molten sulfide solution
Heat Transfer
Conduction
stationary medium
Convection
displacement of particles
Radiation
heat flow in vacuum
Furnaces
Crucible Furnace
Hearth Furnace
Shaft Furnace
Induction Furnace
Electric Arc Furnace
Converter
Retorts
extraction of metals with chemical reactions at high temperatures
Pretreatment
Calcination
heating of ore in absence of air
Roasting
heating of ore with excess air
Heat Exchangers
recycles heat from sources to be used for other processes
Heat Recuperators
continuous transfer of heat
Heat Regenerators
heat storage element that absorbs heat and gives it up
:zap: Electrometallurgy
Electrowinning
uses impure alloy or anode which dissolves due to the action of the current
Electrorefining
electrolytic extraction process in which cathodic reaction is used to recover the valuable metal from the electrolyte which is derived from a leaching process
Electrochemistry
Reduction and Oxidation
Anode and Cathode
Electrolytes
Calculations in Electrochem
Standard Cell Potential
Gibbs Free Energy
Nernst Equation
Thomson Rule
Faraday's Law of Electrolysis
Current Efficiency
a chemical reaction in which there is transfer of electrons from one chemical species to another
Methods of Metal Winning
Crystallization
formation of solid by alteration of the stability of solute in a solvent
Precipitation
by Gases
by Metals (Cementation)
formation of solid from a liquid through chemical reaction as a result of dilution
uses electricity for winning and refining minerals
deals with the extraction of metals from naturally occurring compounds and the subsequent refinement to a purity suitable for commercial use
Sources of Metal
Primary/Natural Sources
Secondary/Recycled Sources
Extraction Processes for Different Metals
Gold
CIP / CIL / CIC
Merill-Crowe Process
Miller Process
Direct Smelting
Wohlwill Process
Nickel
HPAL
Moa Bay Process
Sherritt Gordon Process
Copper
Heap Leaching
Electro-Refining
Flash Smelting
Iron
Basic Oxygen Furnace Smelting
Midrex/COREX Process
Blast Furnace Smelting
:gear: Physical Metallurgy
Chemical Bonding
Ionic
transfer of electrons
Covalent
sharing of electrons
Metallic
electron cloud holds atoms together
Van der Waals
interaction of atomic dipoles
Hydrogen
dipole-dipole attraction between two electronegative + H atoms
Crystallography
Crystalline
long-range ordered internal structure
Amorphous
short-range ordered internal structure
Single Crystal
perfect periodic arrangement without interruption
Polycrystalline
consists of many small crystals separated by grain boundaries
Polymorphism
capability of some materials to possess different crystal structures
Grains
single crystal
Anisotropic
properties are dependent of crystallographic direction
Isotropic
properties are independent on crystallographic direction
Unit Cells
simplest repeating unit in a crystal
Atomic Packing Factor
fraction of space filled by atoms
Grain Boundary
interface between two grains
Metal Properties
Mechanical
Electrical
Thermal
Magnetic
Optical
Deteriorative
Mechanical Loading
Compression
Tension
Shear
Torsion
Bending
Stress-Strain Diagrams
Elastic Deformation
Young's Modulus
Yield Strength
Resilience
when applied stress is removed, material reverts to original
Plastic Deformation
Ultimate Tensile Strength
Fracture Stress
Toughness
Ductility
Hardness
when applied stress is removed, material does NOT revert to original
Stress
force per area of application
Strain
deformation or displacement of material due to applied stress
Dislocation
Screw
dislocation is perpendicular to applied shear stress
Edge
dislocation is parallel to applied shear stress
Slip
Single Crystal Slip
multiple bonds must break at the same time
Polycrystal Slip
atomic bonds can break one at a time
how dislocations move along the crystal lattice
a linear imperfection in a solid wherein some of the atoms are misaligned
Dislocation Density
dislocation length per volume of material
Strengthening Mechanisms
Strain Hardening
plastically deformed
Grain Size Reduction
increase in grain boundaries
Solid Solution Strengthening
impurities
Precipitation Hardening
precipitation of a solute
Restoration Processes
Recovery
recovers original physical properties
Recrystallization
formation of strain-free grains from the old grains
Grain Growth
new grains grow and consume smaller grains
concerned with physical and mechanical properties of metals as affected by composition, processing, and environmental conditions
Potential Energy Curves
describes the energy of repulsion/attraction based on distance between atoms
:wrench: Adaptive Metallurgy
manufacturing of metallic products for the use of society
Fabrication of Metals
Forming Operations
Cold Working
operating temp < T_rec
Hot Working
operating temp > T_rec
Forging
deforming a hot metal by applying successive loads or continuous squeezing
Rolling
passing a piece of metal between rolls in producing long parts
Extrusion
metal bar is forced into a die by compressive force applied by a ram
Drawing
metal bar is forced into a die by a tensile force and pulled out to the other side
Casting
molten metal is poured into a mold cavity and the metal solidifies and assumes the shape of the mold
Centrifugal Casting
Semi-solid Casting
Evaporative Pattern Casting
Investment Casting
Permanent Mold Casting
Pressure Die Casting
Plaster Mold Casting
Continuous Casting
Powder Metallurgy
useful for objects that are hard to cast form
Compaction
metal powders are compacted together
Sintering
compacted object is heated to bond metal powders together
Metal Joining
permanently joining two or more metals together
Soldering
neither parent metal is melted, filler metal has T_m < 450 C
Brazing
neither parent metal is melted, filler metal has T_m > 450 C
Welding
both filler and parent metal are melted
Adhesive Bonding
uses inorganic/organic compounds to bond metals together
Failure of Metals
Fracture
high static (constant) stress at relatively low temperatures
Ductile Fracture
evident deformation and cup-and-cone feature
Brittle Fracture
barely noticable to no evident deformation and chevron markings
Transgranular Fracture
fracture propagates through grains
Intergranular Fracture
fracture propagates along grain boundaries
Ductile-to-Brittle Transition
metal shifts from ductile to brittle behavior with a decrease in temperature
Wear
damage to surface due to mechanical contact between solids
Fatigue
relatively low applied stress fluctuates with time
S-N Cycle
shows the number of cycles needed for a certain stress amplitude to cause failure
Fatigue Limit
horizontal line whose stress amplitude under it will never cause failure after infinite cylces
Stages
Crack Initiation
crack forms at a point of high stress concentration
Crack Propagation
crack advances incrementally during stress cycles
Final Failure
rapid failure once crack reaches critical size
Creep
time-dependent application of stress at relatively high temperature
cracks propagate along grain boundaries due to their weakened state at higher temperatures
Stages
Primary Creep
decrease in creep rate due to strain hardening effects
Secondary Creep
competing processes of strain hardening and recovery
Tertiary Creep
microstructural changes bring about accelerated creep rate and failure
Corrosion
deteriorative chemical reaction that leads to dissolution of metal or formation of nonmetallic film
Electrochemical Reactions
metal is oxidized produces nonmetallic scales or films
Galvanic Series
helps determine which is more susceptible to corrosion
:pick: Mineral Processing
Unit Operations
Communition
Equations
Rittinger's Law
Kick's Law
Bond's Law
Bond's Work Index Equation
Stages and Equipment
Crushing
Primary Crusher
Jaw Crusher
Blake Type
Dodge Type
Gyratory Crusher
Secondary Crusher
Impactors
Cone Crusher
Roll Crusher
Grinding
Ball Mill
Rod Mill
Autogenous/Semi-autogenous Mill
Tower Mill
Motions of Charges
Cataracting
Cascading
Centrifuging
Sizing
Screening
Static Grizzlies
Sieve Bends
Grizzly Screen
Trommels
Classification
Hydrocyclone
Rake Classifier
Spiral Classifier
Concentration
Gravity Concentration
Dense Media Separation
Vertical Current Separation
Jigging
Streaming Current Separation
Shaking Table
Froth Flotation
High-Tension Separation
Magnetic Separation
Dewatering
Sedimentation
Coagulation
Flocculation
Filtration
Thermal Drying
Auxiliary Operations
Ore Handling
Gravity should be maximized
As short as possible
Ore Transportation
for Dry Ores
Chutes
Conveyor Belts
Gravity Bucket Elevators
for Wet Ores
Launders
Pipelines
Centrifugal Pumps
Ore Storage
Stockpiles
Ore Bins
Slurry Tanks
Ore Feeding
Chain Feeders
Apron Feeders
Vibrating Grizzlies
Elliptical Bar Feeder
Removal of
Harmful Materials
Hand Sorting
Magnetic Separator
Vibrating Scalping Screens
Washing
Tailing Disposal
Recycling
Use as Construction
Materials
Back-filling
Tailings Dam
Terms
Mineral
Solids with definite chemical composition and ordered crystal structure
Concentrate
valuable minerals obtained from the recovery process
Gangue
minerals of no value
Run-of-mine
as-mined ore which consists of your valuable minerals and gangue
Tailing
predominantly the gangue mineral
Cutoff Grade
minimum grade that is considered economical
Grade
measure of the concentration of metal in an ore
is the art and technology of treating ores from the mining areas in order to separate the valuable minerals from the waste rock
:fuelpump: Metallurgical Fuels
Solids
Coal
Coke
Charcoal
Lignite
Wood
Liquids
Petroleum
Tar
Petroleum distillates
Alcohols
Gaseous
Natural Gas
City gas
Coal gas
Coke gas
:evergreen_tree: Environmental Impacts
Environmental Engineering
the application of science and engineering principles to manage and improve the environment
Pollutants in Metallurgy
Iron and steelmaking
slags, blast furnace fumes, cyanides, electric furnace dust
Ferroalloys
arsine, phosphine, silica dust
Aluminum
mercury, red mud fluorite compounds, toxic organic compounds, cyanides
Electroplating
chromium, copper, nickel
Air Quality Management
Sources of Air Pollution
Area Source
pollutants are released in a wide area
Stationary Source
any building or immobile structure which emits any air pollutant
Point Source
any contaminant that is released from an easily identified and confined place
Mobile Source
any vehicle propelled by or through combustion for conveyance of persons or goods
Sampling
High and low volume samplers
instruments used to collect samples of air particles
High Volume
1500 cubic meters of air over a 24-hour period
Low Volume
only 24 cubic meters or less
Total suspended particulates (TSP)
monitoring measures the amount of particles suspended in the atmosphere
<100 micrometers in diameter
Philippine Clean Air Act of 1999
Water Quality Management
Philippine Clean Water Act of 2004
Adsorption
process in which material (absorbate) travels from a gas or liquid phase and forms a superficial monomolecular layer on a solid or liquid condensed phase (substrate)
Activated Carbon
purified powdered charcoal with large adsorptive surface area
can have surface greater than 1000 square meter / gram
Solid Waste and Hazardous Materials Management
Ecological Solid Waste Management Act of 2000
Solid Waste
all discarded household, commercial waste, non-hazardous solid waste
Toxic Substances and Hazardous and Nuclear Wastes Control Act of 1990
Hazardous Wastes
substances that are without any safe commercial, industrial, agricultural, or economic usage