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Metal Ore
Ore concentrate, dressed ore or simply concentrate is the product generally produced by metal ore mines. The raw ore is usually ground finely in various comminution operations and gangue (waste) is removed, thus concentrating the metal component. The concentrate is then transported to various physical or chemical processes called hydrometallurgy, pyrometallurgy smelters, and electrometallurgy where it is used to produce useful metals. Ore concentrates are classified as a hazardous cargo for shipping by the International Maritime Solid Bulk Cargoes (IMSBC) Code, which is part of the SOLAS Convention, due to their tendency under certain conditions, to liquefy, which may affect the stability of the ship due to the free surface effect potentially causing a ship to capsize Capsizing or keeling over occurs when a boat or ship is rolled on its side or further by wave action, instability or wind force beyond the angle of positive static stability or it is upside down in the water. T ...
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Metal
A metal (from Greek μέταλλον ''métallon'', "mine, quarry, metal") is a material that, when freshly prepared, polished, or fractured, shows a lustrous appearance, and conducts electricity and heat relatively well. Metals are typically ductile (can be drawn into wires) and malleable (they can be hammered into thin sheets). These properties are the result of the ''metallic bond'' between the atoms or molecules of the metal. A metal may be a chemical element such as iron; an alloy such as stainless steel; or a molecular compound such as polymeric sulfur nitride. In physics, a metal is generally regarded as any substance capable of conducting electricity at a temperature of absolute zero. Many elements and compounds that are not normally classified as metals become metallic under high pressures. For example, the nonmetal iodine gradually becomes a metal at a pressure of between 40 and 170 thousand times atmospheric pressure. Equally, some materials regarded as metals ...
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Mining
Mining is the extraction of valuable minerals or other geological materials from the Earth, usually from an ore body, lode, vein, seam, reef, or placer deposit. The exploitation of these deposits for raw material is based on the economic viability of investing in the equipment, labor, and energy required to extract, refine and transport the materials found at the mine to manufacturers who can use the material. Ores recovered by mining include metals, coal, oil shale, gemstones, limestone, chalk, dimension stone, rock salt, potash, gravel, and clay. Mining is required to obtain most materials that cannot be grown through agricultural processes, or feasibly created artificially in a laboratory or factory. Mining in a wider sense includes extraction of any non-renewable resource such as petroleum, natural gas, or even water. Modern mining processes involve prospecting for ore bodies, analysis of the profit potential of a proposed mine, extraction of the desired materials, an ...
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Comminution
Comminution is the reduction of solid materials from one average particle size to a smaller average particle size, by crushing, grinding, cutting, vibrating, or other processes. In geology, it occurs naturally during faulting in the upper part of the Earth's crust. In industry, it is an important unit operation in mineral processing, ceramics, electronics, and other fields, accomplished with many types of mill. In dentistry, it is the result of mastication of food. In general medicine, it is one of the most traumatic forms of bone fracture. Within industrial uses, the purpose of comminution is to reduce the size and to increase the surface area of solids. It is also used to free useful materials from matrix materials in which they are embedded, and to concentrate minerals. Energy requirements The comminution of solid materials consumes energy, which is being used to break up the solid into smaller pieces. The comminution energy can be estimated by: * Rittinger's law, which assu ...
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Gangue
In mining, gangue () is the commercially worthless material that surrounds, or is closely mixed with, a wanted mineral in an ore deposit. It is thus distinct from overburden, which is the waste rock or materials overlying an ore or mineral body that are displaced during mining without being processed, and from tailings, which is rock already stripped of valuable minerals. The separation of valuable mineral from gangue minerals is known as mineral processing, mineral dressing, or ore dressing. It is a necessary, and often significant, aspect of mining. It can be a complicated process, depending on the nature of the minerals involved. For example, galena, an ore of lead, is usually found in large pieces within its gangue, so it does not normally need extensive processing to remove it; but cassiterite, the chief ore mineral of tin, is usually disseminated as very small crystals throughout its gangue, so when it is mined from hard rock, the ore-bearing rock first needs to be crushed ...
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Hydrometallurgy
Hydrometallurgy is a technique within the field of extractive metallurgy, the obtaining of metals from their ores. Hydrometallurgy involve the use of aqueous solutions for the recovery of metals from ores, concentrates, and recycled or residual materials.Brent Hiskey "Metallurgy, Survey" in Kirk-Othmer Encyclopedia of Chemical Technology, 2000, Wiley-VCH, Weinheim. Processing techniques that complement hydrometallurgy are pyrometallurgy, vapour metallurgy, and molten salt electrometallurgy. Hydrometallurgy is typically divided into three general areas: *Leaching *Solution concentration and purification *Metal or metal compound recovery Leaching Leaching involves the use of aqueous solutions to extract metal from metal bearing materials which is brought into contact with a material containing a valuable metal. The first examples come from 11-12th centuries China where it was applied to extraction of copper and accounted for a significant share of total copper production. In the 1 ...
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Pyrometallurgy
Pyrometallurgy is a branch of extractive metallurgy. It consists of the thermal treatment of minerals and metallurgical ores and concentrates to bring about physical and chemical transformations in the materials to enable recovery of valuable metals. Pyrometallurgical treatment may produce products able to be sold such as pure metals, or intermediate compounds or alloys, suitable as feed for further processing. Examples of elements extracted by pyrometallurgical processes include the oxides of less reactive elements like iron, copper, zinc, chromium, tin, and manganese. Pyrometallurgical processes are generally grouped into one or more of the following categories: * calcining, * roasting, * smelting, * refining. Most pyrometallurgical processes require energy input to sustain the temperature at which the process takes place. The energy is usually provided in the form of combustion or from electrical heat. When sufficient material is present in the feed to sustain the proce ...
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Smelting
Smelting is a process of applying heat to ore, to extract a base metal. It is a form of extractive metallurgy. It is used to extract many metals from their ores, including silver, iron, copper, and other base metals. Smelting uses heat and a chemical reducing agent to decompose the ore, driving off other elements as gases or slag and leaving the metal base behind. The reducing agent is commonly a fossil fuel source of carbon, such as coke—or, in earlier times, charcoal. The oxygen in the ore binds to carbon at high temperatures due to the lower potential energy of the bonds in carbon dioxide (). Smelting most prominently takes place in a blast furnace to produce pig iron, which is converted into steel. The carbon source acts as a chemical reactant to remove oxygen from the ore, yielding the purified metal element as a product. The carbon source is oxidized in two stages. First, the carbon (C) combusts with oxygen (O2) in the air to produce carbon monoxide (CO). Second, the ...
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Electrometallurgy
Electrometallurgy is a method in metallurgy that uses electrical energy to produce metals by electrolysis. It is usually the last stage in metal production and is therefore preceded by pyrometallurgical or hydrometallurgical operations. The electrolysis can be done on a molten metal oxide (smelt electrolysis) which is used for example to produce aluminium from aluminium oxide via the Hall-Hérault process. Electrolysis can be used as a final refining stage in pyrometallurgical metal production (electrorefining) and it is also used for reduction of a metal from an aqueous metal salt solution produced by hydrometallurgy (electrowinning). Processes Electrometallurgy is the field concerned with the processes of metal electrodeposition. There are four categories of these processes: *Electrolysis *Electrowinning, the extraction of metal from ores *Electrorefining, the purification of metals. Metal powder production by electrodeposition is included in this category, or sometimes e ...
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Ship
A ship is a large watercraft that travels the world's oceans and other sufficiently deep waterways, carrying cargo or passengers, or in support of specialized missions, such as defense, research, and fishing. Ships are generally distinguished from boats, based on size, shape, load capacity, and purpose. Ships have supported exploration, trade, warfare, migration, colonization, and science. After the 15th century, new crops that had come from and to the Americas via the European seafarers significantly contributed to world population growth. Ship transport is responsible for the largest portion of world commerce. The word ''ship'' has meant, depending on the era and the context, either just a large vessel or specifically a ship-rigged sailing ship with three or more masts, each of which is square-rigged. As of 2016, there were more than 49,000 merchant ships, totaling almost 1.8 billion dead weight tons. Of these 28% were oil tankers, 43% were bulk carriers, and ...
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SOLAS Convention
The International Convention for the Safety of Life at Sea (SOLAS) is an international maritime treaty that sets minimum safety standards in the construction, equipment and operation of merchant ships. The International Maritime Organization convention requires signatory flag states to ensure that ships flagged by them comply with at least these standards. The current version of SOLAS is the 1974 version, known as SOLAS 1974, which came into force on 25 May 1980. , SOLAS 1974 has 167 contracting states, which flag about 99% of merchant ships around the world in terms of gross tonnage. SOLAS in its successive forms is generally regarded as the most important of all international treaties concerning the safety of merchant ships. Signatories The non-parties to SOLAS 1974 include numerous landlocked countries (for obvious reasons), as well as El Salvador, Micronesia and East Timor. Some others including Bolivia, Lebanon and Sri Lanka, all considered flag of convenience states, a ...
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Free Surface Effect
The free surface effect is a mechanism which can cause a watercraft to become unstable and capsize. It refers to the tendency of liquids — and of unbound aggregates of small solid objects, like seeds, gravel, or crushed ore, whose behavior approximates that of liquids — to move in response to changes in the attitude of a craft's cargo holds, decks, or liquid tanks in reaction to operator-induced motions (or sea states caused by waves and wind acting upon the craft). When referring to the free surface effect, the condition of a tank that is not full is described as a "slack tank", while a full tank is "pressed up". Stability and equilibrium In a normally loaded vessel any rolling from perpendicular is countered by a righting moment generated from the increased volume of water displaced by the hull on the lowered side. This assumes the center of gravity of the vessel is relatively constant. If a moving mass inside the vessel moves in the direction of the roll, this counters t ...
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Capsize
Capsizing or keeling over occurs when a boat or ship is rolled on its side or further by wave action, instability or wind force beyond the angle of positive static stability or it is upside down in the water. The act of recovering a vessel from a capsize is called righting. Capsize may result from broaching, , loss of stability due to cargo shifting or flooding, or in high speed boats, from turning too fast. If a capsized vessel has enough flotation to prevent sinking, it may recover on its own in changing conditions or through mechanical work if it is not stable inverted. Vessels of this design are called self-righting. Small vessels In dinghy sailing, a practical distinction can be made between being knocked down (to 90 degrees; on its beam-ends, figuratively) which is called a capsize, and being inverted, which is called being turtled. Small dinghies frequently capsize in the normal course of use and can usually be recovered by the crew. Some types of dinghy are occa ...
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