Zinc Smelting
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Zinc Smelting
Zinc smelting is the process of converting zinc concentrates (ores that contain zinc) into pure zinc. Zinc smelting has historically been more difficult than the smelting of other metals, e.g. iron, because in contrast, zinc has a low boiling point. At temperatures typically used for smelting metals, zinc is a gas that will escape from a furnace with the flue gas and be lost, unless specific measures are taken to prevent it. The most common zinc concentrate processed is zinc sulfide,. which is obtained by concentrating sphalerite using the froth flotation method. Secondary (recycled) zinc material, such as zinc oxide, is also processed with the zinc sulfide.. Approximately 30% of all zinc produced is from recycled sources. Methods There are two methods of smelting zinc: the pyrometallurgical process and the electrolysis process. Both methods are still used. Both of these processes share the same first step: roasting. Roasting Roasting is a process of oxidizing zinc sulfide co ...
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Zinc
Zinc is a chemical element with the symbol Zn and atomic number 30. Zinc is a slightly brittle metal at room temperature and has a shiny-greyish appearance when oxidation is removed. It is the first element in group 12 (IIB) of the periodic table. In some respects, zinc is chemically similar to magnesium: both elements exhibit only one normal oxidation state (+2), and the Zn2+ and Mg2+ ions are of similar size.The elements are from different metal groups. See periodic table. Zinc is the 24th most abundant element in Earth's crust and has five stable isotopes. The most common zinc ore is sphalerite (zinc blende), a zinc sulfide mineral. The largest workable lodes are in Australia, Asia, and the United States. Zinc is refined by froth flotation of the ore, roasting, and final extraction using electricity ( electrowinning). Zinc is an essential trace element for humans, animals, plants and for microorganisms and is necessary for prenatal and postnatal development. It ...
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Cadmium
Cadmium is a chemical element with the symbol Cd and atomic number 48. This soft, silvery-white metal is chemically similar to the two other stable metals in group 12, zinc and mercury. Like zinc, it demonstrates oxidation state +2 in most of its compounds, and like mercury, it has a lower melting point than the transition metals in groups 3 through 11. Cadmium and its congeners in group 12 are often not considered transition metals, in that they do not have partly filled ''d'' or ''f'' electron shells in the elemental or common oxidation states. The average concentration of cadmium in Earth's crust is between 0.1 and 0.5 parts per million (ppm). It was discovered in 1817 simultaneously by Stromeyer and Hermann, both in Germany, as an impurity in zinc carbonate. Cadmium occurs as a minor component in most zinc ores and is a byproduct of zinc production. Cadmium was used for a long time as a corrosion-resistant plating on steel, and cadmium compounds are used as red, orang ...
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Avonmouth Docks
The Avonmouth Docks are part of the Port of Bristol, in England. They are situated on the northern side of the mouth of the River Avon, opposite the Royal Portbury Dock on the southern side, where the river joins the Severn estuary, within Avonmouth. Accessible via a long and wide lock, today the docks are one of the UK's major ports for chilled foods, especially fruit and vegetables. Land-side freight access and distribution is via either the M5 motorway or the Henbury Loop Line, whilst rail-passenger access is via Avonmouth railway station on the Severn Beach Line. Background Bristol Harbour had always been a major centre of trade within the wider UK economy, due to its strategic location to the west of the country, allowing access to both the Atlantic Ocean and the Mediterranean. Coastal trade was also important, with the area called "Welsh Back" concentrating on trows with cargoes from the Slate industry in Wales, stone, timber and coal. However, by the 18th century the ...
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National Smelting Company
The National Smelting Company was a nationalised zinc smelting company in Avonmouth, England. It was established by Minister of Munitions Winston Churchill to produce mustard gas during World War I. After World War I, it was bought by private business interests. From 1929 it became part of Australia's Imperial Smelting Corporation. The site – also known as the Britannia smelting works – was where the Imperial Smelting Process was developed. From 1967, the Avonmouth Works was home to the largest and most efficient zinc blast furnace in the world. The site remained operational until 2003 when the production of zinc, cadmium, lead and sulphuric acid ceased. The site is being redeveloped as a supermarket distribution centre for Asda and a recycling plant for SITA UK. Background During the later part of World War I, it was proposed to make Avonmouth Docks the UK centre of production of dichloroethyl sulphide, also known as mustard gas. However, its production was against the H ...
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New Jersey Zinc Company
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Zinc Refining
Zinc refining is the process of purifying zinc to ''special high grade'' (SHG) zinc, which is at least 99.995% pure. This process is not usually required when smelting of zinc is done through electrolysis processes, but is needed when zinc is produced by pyrometallurgical processes, because it is only 98.5% pure. There are various refining methods, but the refluxing process is the most commonly used. High purity zinc is required industrially to avoid zinc pest, a slow distortion and cracking of zinc die castings caused by impurities precipitating out. Refluxing process The New Jersey Zinc Company invented this process in 1930. The process take advantage of the relatively low boiling point of zinc () as compared to the impurities being removed in the first "column": iron and aluminium. Therefore, in the first column the zinc is heated above its boiling point and allowed to rise to a condenser. The iron and aluminium impurities sink to the bottom in the form of a solid or liquid. Th ...
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Aluminium
Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. It has a great affinity towards oxygen, and forms a protective layer of oxide on the surface when exposed to air. Aluminium visually resembles silver, both in its color and in its great ability to reflect light. It is soft, non-magnetic and ductile. It has one stable isotope, 27Al; this isotope is very common, making aluminium the twelfth most common element in the Universe. The radioactivity of 26Al is used in radiodating. Chemically, aluminium is a post-transition metal in the boron group; as is common for the group, aluminium forms compounds primarily in the +3 oxidation state. The aluminium cation Al3+ is small and highly charged; as such, it is polarizing, and bonds aluminium forms tend towards covalency. The strong affinity tow ...
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Electrowinning
Electrowinning, also called electroextraction, is the electrodeposition of metals from their ores that have been put in solution via a process commonly referred to as leaching. Electrorefining uses a similar process to remove impurities from a metal. Both processes use electroplating on a large scale and are important techniques for the economical and straightforward purification of non-ferrous metals. The resulting metals are said to be ''electrowon''. In electrowinning, an electrical current is passed from an inert anode (oxidation, made out of lead (Pb)) through a ''leach'' solution containing the dissolved metal ions so that the metal is recovered as it is deposited in an electroplating process onto the cathode (reduction, stainless steel, aluminium (Al), titanium (Ti)). In electrorefining, the anode consists of the impure metal (e.g., copper) to be refined. The impure metallic anode is oxidized and the metal dissolves into solution. The metal ions migrate through the acidic ...
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Thallium
Thallium is a chemical element with the Symbol (chemistry), symbol Tl and atomic number 81. It is a gray post-transition metal that is not found free in nature. When isolated, thallium resembles tin, but discolors when exposed to air. Chemists William Crookes and Claude-Auguste Lamy discovered thallium independently in 1861, in residues of sulfuric acid production. Both used the newly developed method of flame spectroscopy, in which thallium produces a notable green spectral line. Thallium, from Greek language, Greek , , meaning "green shoot" or "twig", was named by Crookes. It was isolated by both Lamy and Crookes in 1862; Lamy by electrolysis, and Crookes by precipitation and melting of the resultant powder. Crookes exhibited it as a powder precipitated by zinc at the international exhibition, which opened on 1 May that year. Thallium tends to form the +3 and +1 oxidation states. The +3 state resembles that of the other elements in Boron Group, group 13 (boron, aluminium, galli ...
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Nickel
Nickel is a chemical element with symbol Ni and atomic number 28. It is a silvery-white lustrous metal with a slight golden tinge. Nickel is a hard and ductile transition metal. Pure nickel is chemically reactive but large pieces are slow to react with air under standard conditions because a passivation layer of nickel oxide forms on the surface that prevents further corrosion. Even so, pure native nickel is found in Earth's crust only in tiny amounts, usually in ultramafic rocks, and in the interiors of larger nickel–iron meteorites that were not exposed to oxygen when outside Earth's atmosphere. Meteoric nickel is found in combination with iron, a reflection of the origin of those elements as major end products of supernova nucleosynthesis. An iron–nickel mixture is thought to compose Earth's outer and inner cores. Use of nickel (as natural meteoric nickel–iron alloy) has been traced as far back as 3500 BCE. Nickel was first isolated and classified as an e ...
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Germanium
Germanium is a chemical element with the symbol Ge and atomic number 32. It is lustrous, hard-brittle, grayish-white and similar in appearance to silicon. It is a metalloid in the carbon group that is chemically similar to its group neighbors silicon and tin. Like silicon, germanium naturally reacts and forms complexes with oxygen in nature. Because it seldom appears in high concentration, germanium was discovered comparatively late in the discovery of the elements. Germanium ranks near fiftieth in relative abundance of the elements in the Earth's crust. In 1869, Dmitri Mendeleev predicted its existence and some of its properties from its position on his periodic table, and called the element ekasilicon. In 1886, Clemens Winkler at Freiberg University found the new element, along with silver and sulfur, in the mineral argyrodite. Winkler named the element after his country, Germany. Germanium is mined primarily from sphalerite (the primary ore of zinc), though germanium is ...
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Cobalt
Cobalt is a chemical element with the symbol Co and atomic number 27. As with nickel, cobalt is found in the Earth's crust only in a chemically combined form, save for small deposits found in alloys of natural meteoric iron. The free element, produced by reductive smelting, is a hard, lustrous, silver-gray metal. Cobalt-based blue pigments ( cobalt blue) have been used since ancient times for jewelry and paints, and to impart a distinctive blue tint to glass, but the color was for a long time thought to be due to the known metal bismuth. Miners had long used the name ''kobold ore'' (German for ''goblin ore'') for some of the blue-pigment-producing minerals; they were so named because they were poor in known metals, and gave poisonous arsenic-containing fumes when smelted. In 1735, such ores were found to be reducible to a new metal (the first discovered since ancient times), and this was ultimately named for the ''kobold''. Today, some cobalt is produced specifically from one of ...
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