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Extractive metallurgy is a branch of
metallurgical engineering Metallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their inter-metallic compounds, and their mixtures, which are known as alloys. Metallurgy encompasses both the sc ...
wherein process and methods of extraction of metals from their natural
mineral deposit Ore is natural rock or sediment that contains one or more valuable minerals, typically containing metals, that can be mined, treated and sold at a profit.Encyclopædia Britannica. "Ore". Encyclopædia Britannica Online. Retrieved 7 April 2 ...
s are studied. The field is a materials science, covering all aspects of the types of ore, washing, concentration, separation, chemical processes and extraction of pure metal and their
alloying An alloy is a mixture of chemical elements of which at least one is a metal. Unlike chemical compounds with metallic bases, an alloy will retain all the properties of a metal in the resulting material, such as electrical conductivity, ductility ...
to suit various applications, sometimes for direct use as a finished product, but more often in a form that requires further working to achieve the given properties to suit the applications. The field of ferrous and non-ferrous extractive metallurgy have specialties that are generically grouped into the categories of
mineral processing In the field of extractive metallurgy, mineral processing, also known as ore dressing, is the process of separating commercially valuable minerals from their ores. History Before the advent of heavy machinery the raw ore was broken up using ...
,
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 m ...
,
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 ...
, and
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 electr ...
based on the process adopted to extract the metal. Several processes are used for extraction of same metal depending on occurrence and chemical requirements.


Mineral processing

Mineral processing In the field of extractive metallurgy, mineral processing, also known as ore dressing, is the process of separating commercially valuable minerals from their ores. History Before the advent of heavy machinery the raw ore was broken up using ...
begins with beneficiation, consisting of initially breaking down the ore to required sizes depending on the concentration process to be followed, by crushing, grinding, sieving etc. Thereafter, the ore is physically separated from any unwanted impurity, depending on the form of occurrence and or further process involved. Separation processes take advantage of physical properties of the materials. These physical properties can include density, particle size and shape, electrical and magnetic properties, and surface properties. Major physical and chemical methods include magnetic separation,
froth flotation Froth flotation is a process for selectively separating hydrophobic materials from hydrophilic. This is used in mineral processing, paper recycling and waste-water treatment industries. Historically this was first used in the mining industry, wher ...
, leaching etc., whereby the impurities and unwanted materials are removed from the ore and the base ore of the metal is concentrated, meaning the percentage of metal in the ore is increased. This concentrate is then either processed to remove moisture or else used as is for extraction of the metal or made into shapes and forms that can undergo further processing, with ease of handling. Ore bodies often contain more than one valuable metal. Tailings of a previous process may be used as a feed in another process to extract a secondary product from the original ore. Additionally, a concentrate may contain more than one valuable metal. That concentrate would then be processed to separate the valuable metals into individual constituents.


Hydrometallurgy

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 m ...
is concerned with processes involving
aqueous An aqueous solution is a solution in which the solvent is water. It is mostly shown in chemical equations by appending (aq) to the relevant chemical formula. For example, a solution of table salt, or sodium chloride (NaCl), in water would be rep ...
solutions to extract metals from ores. The first step in the hydrometallurgical process is
leaching Leaching is the loss or extraction of certain materials from a carrier into a liquid (usually, but not always a solvent). and may refer to: * Leaching (agriculture), the loss of water-soluble plant nutrients from the soil; or applying a small amou ...
, which involves dissolution of the valuable metals into the aqueous solution and or a suitable solvent. After the solution is separated from the ore solids, the extract is often subjected to various processes of purification and concentration before the valuable metal is recovered either in its metallic state or as a chemical compound. This may include
precipitation In meteorology, precipitation is any product of the condensation of atmospheric water vapor that falls under gravitational pull from clouds. The main forms of precipitation include drizzle, rain, sleet, snow, ice pellets, graupel and hail. ...
,
distillation Distillation, or classical distillation, is the process of separation process, separating the components or substances from a liquid mixture by using selective boiling and condensation, usually inside an apparatus known as a still. Dry distilla ...
,
adsorption Adsorption is the adhesion of atoms, ions or molecules from a gas, liquid or dissolved solid to a surface. This process creates a film of the ''adsorbate'' on the surface of the ''adsorbent''. This process differs from absorption, in which a f ...
, and
solvent extraction A solvent (s) (from the Latin '' solvō'', "loosen, untie, solve") is a substance that dissolves a solute, resulting in a solution. A solvent is usually a liquid but can also be a solid, a gas, or a supercritical fluid. Water is a solvent for ...
. The final recovery step may involve precipitation, cementation, or an electrometallurgical process. Sometimes, hydrometallurgical processes may be carried out directly on the ore material without any pretreatment steps. More often, the ore must be pretreated by various mineral processing steps, and sometimes by pyrometallurgical processes.


Pyrometallurgy

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 ...
involves high temperature processes where chemical reactions take place among gases, solids, and molten materials. Solids containing valuable metals are treated to form intermediate compounds for further processing or converted into their elemental or metallic state. Pyrometallurgical processes that involve gases and solids are typified by
calcining Calcination refers to thermal treatment of a solid chemical compound (e.g. mixed carbonate ores) whereby the compound is raised to high temperature without melting under restricted supply of ambient oxygen (i.e. gaseous O2 fraction of air), genera ...
and
roasting Roasting is a cooking method that uses dry heat where hot air covers the food, cooking it evenly on all sides with temperatures of at least from an open flame, oven, or other heat source. Roasting can enhance the flavor through caramelization ...
operations. Processes that produce molten products are collectively referred to as
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 ch ...
operations. The energy required to sustain the high temperature pyrometallurgical processes may derive from the exothermic nature of the chemical reactions taking place. Typically, these reactions are oxidation, e.g. of sulfide to
sulfur dioxide Sulfur dioxide (IUPAC-recommended spelling) or sulphur dioxide (traditional Commonwealth English) is the chemical compound with the formula . It is a toxic gas responsible for the odor of burnt matches. It is released naturally by volcanic activ ...
. Often, however, energy must be added to the process by combustion of fuel or, in the case of some smelting processes, by the direct application of electrical energy.
Ellingham diagram An Ellingham diagram is a graph showing the temperature dependence of the stability of compounds. This analysis is usually used to evaluate the ease of reduction of metal oxides and sulfides. These diagrams were first constructed by Harold Ellin ...
s are a useful way of analysing the possible reactions, and so predicting their outcome.


Electrometallurgy

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 electr ...
involves metallurgical processes that take place in some form of
electrolytic cell An electrolytic cell is an electrochemical cell that utilizes an external source of electrical energy to force a chemical reaction that would not otherwise occur. The external energy source is a voltage applied between the cell′s two electrod ...
. The most common types of electrometallurgical processes are
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 ...
and
electro-refining 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 ...
. Electrowinning is an electrolysis process used to recover metals in aqueous solution, usually as the result of an ore having undergone one or more hydrometallurgical processes. The metal of interest is plated onto the cathode, while the anode is an inert electrical conductor. Electro-refining is used to dissolve an impure metallic anode (typically from a smelting process) and produce a high purity cathode. Fused salt electrolysis is another electrometallurgical process whereby the valuable metal has been dissolved into a molten salt which acts as the electrolyte, and the valuable metal collects on the cathode of the cell. The fused salt electrolysis process is conducted at temperatures sufficient to keep both the electrolyte and the metal being produced in the molten state. The scope of electrometallurgy has significant overlap with the areas of hydrometallurgy and (in the case of fused salt electrolysis) pyrometallurgy. Additionally,
electrochemical Electrochemistry is the branch of physical chemistry concerned with the relationship between electrical potential difference, as a measurable and quantitative phenomenon, and identifiable chemical change, with the potential difference as an outco ...
phenomena play a considerable role in many mineral processing and hydrometallurgical processes.


Ionometallurgy

Mineral processing and extraction of metals are very energy-intensive processes, which are not exempted of producing large volumes of solid residues and wastewater, which also require energy to be further treated and disposed. Moreover, as the demand for metals increases, the metallurgical industry must rely on sources of materials with lower metal contents both from a primary (e.g., mineral ores) and/or secondary (e.g., slags, tailings, municipal waste) raw materials. Consequently, mining activities and waste recycling must evolve towards the development of more selective, efficient and environmentally friendly mineral and metal processing routes. Mineral processing operations are needed firstly to concentrate the mineral phases of interest and reject the unwanted material physical or chemically associated to a defined raw material. The process, however, demand about 30 GJ/tonne of metal, which accounts about 29% of the total energy spent on mining in the USA. Meanwhile,
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 ...
is a significant producer of greenhouse gas emissions and harmful flue dust.
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 m ...
entails the consumption of large volumes of lixiviants such as H2SO4, HCl, KCN, NaCN which have poor selectivity. Moreover, despite the environmental concern and the use restriction imposed by some countries, cyanidation is still considered the prime process technology to recover gold from ores. Mercury is also used by artisanal miners in less economically developed countries to concentrate gold and silver from minerals, despite its obvious toxicity. Bio-hydro-metallurgy make use of living organisms, such as bacteria and fungi, and although this method demands only the input of and from the atmosphere, it requires low solid-to-liquid ratios and long contact times, which significantly reduces space-time yields. Ionometallurgy makes use of non-aqueous ionic solvents such ionic liquids (ILs) and deep eutectic solvents (DESs), which allows the development of closed-loop flow sheet to effectively recover metals by, for instance, integrating the metallurgical unit operations of leaching and electrowinning. It allows to process metals at moderate temperatures in a non-aqueous environment which allows controlling metal speciation, tolerates impurities and at the same time exhibits suitable solubilities and current efficiencies. This simplify conventional processing routes and allows a substantial reduction in the size of a metal processing plant.


Metal extraction with ionic fluids

DESs are fluids generally composed of two or three cheap and safe components that are capable of self-association, often through hydrogen bond interactions, to form eutectic mixtures with a melting point lower than that of each individual component. DESs are generally liquid at temperatures lower than 100 °C, and they exhibit similar physico-chemical properties to traditional ILs, while being much cheaper and environmentally friendlier. Most of them are mixtures of choline chloride and a hydrogen-bond donor (e.g., urea, ethylene glycol, malonic acid) or mixtures of choline chloride with a hydrated metal salt. Other choline salts (e.g. acetate, citrate, nitrate) have a much higher costs or need to be synthesised, and the DES formulated from these anions are typically much more viscous and can have higher conductivities than for choline chloride. This results in lower plating rates and poorer throwing power and for this reason chloride-based DES systems are still favoured. For instance, Reline (a 1:2 mixture of choline chloride and urea) has been used to selectively recover Zn and Pb from a mixed metal oxide matrix. Similarly, Ethaline (a 1: 2 mixture of choline chloride and ethylene glycol) facilitates metal dissolution in electropolishing of steels. DESs have also demonstrated promising results to recover metals from complex mixtures such Cu/Zn and Ga/As, and precious metals from minerals. It has also been demonstrated that metals can be recovered from complex mixtures by electrocatalysis using a combination of DESs as lixiviants and an oxidising agent, while metal ions can be simultaneously separated from the solution by electrowinning.


Recovery of precious metals by ionometallurgy

Precious metals are rare, naturally occurring metallic chemical elements of high economic value. Chemically, the precious metals tend to be less reactive than most elements. They include gold and silver, but also the so-called platinum group metals: ruthenium, rhodium, palladium, osmium, iridium, and platinum (see precious metals). Extraction of these metals from their corresponding hosting minerals would typically require pyrometallurgy (e.g., roasting), hydrometallurgy (cyanidation), or both as processing routes. Early studies have demonstrated that gold dissolution rate in Ethaline compares very favourably to the cyanidation method, which is further enhanced by the addition of iodine as an oxidising agent. In an industrial process the iodine has the potential to be employed as an electrocatalyst, whereby it is continuously recovered in situ from the reduced iodide by electrochemical oxidation at the anode of an electrochemical cell. Dissolved metals can be selectively deposited at the cathode by adjusting the electrode potential. The method also allows better selectivity as part of the gangue (e.g., pyrite) tend to be dissolved more slowly. Sperrylite (PtAs2) and moncheite (PtTe2), which are typically the more abundant platinum minerals in many orthomagmatic deposits, do not react under the same conditions in Ethaline because they are disulphide (pyrite), diarsenide (sperrylite) or ditellurides (calaverite and moncheite) minerals, which are particularly resistant to iodine oxidation. The reaction mechanism by which dissolution of platinum minerals is taking place is still under investigation.


Metal recovery from sulfide minerals with ionometallurgy

Metal sulfides (e.g., pyrite FeS2, arsenopyrite FeAsS, chalcopyrite CuFeS2) are normally processed by chemical oxidation either in aqueous media or at high temperatures. In fact, most base metals, e.g., aluminium, chromium, must be (electro)chemically reduced at high temperatures by which the process entails a high energy demand, and sometimes large volumes of aqueous waste is generated. In aqueous media chalcopyrite, for instance, is more difficult to dissolve chemically than covellite and chalcocite due to surface effects (formation of polysulfide species,). The presence of Cl ions has been suggested to alter the morphology of any sulfide surface formed, allowing the sulfide mineral to leach more easily by preventing passivation. DESs provide a high Cl ion concentration and low water content, whilst reducing the need for either high additional salt or acid concentrations, circumventing most oxide chemistry. Thus, the electrodissolution of sulfide minerals has demonstrated promising results in DES media in absence of passivation layers, with the release into the solution of metal ions which could be recovered from solution. During extraction of copper from copper sulfide minerals with Ethaline, chalcocite (Cu2S) and covellite (CuS) produce a yellow solution, indicating that uCl4sup>2− complex are formed. Meanwhile, in the solution formed from chalcopyrite, Cu2+ and Cu+ species co-exist in solution due to the generation of reducing Fe2+ species at the cathode. The best selective recovery of copper (>97%) from chalcopyrite can be obtained with a mixed DES of 20 wt.% ChCl-oxalic acid and 80 wt.% Ethaline.


Metal recovery from oxide compounds with Ionometallurgy

Recovery of metals from oxide matrixes is generally carried out using mineral acids. However, electrochemical dissolution of metal oxides in DES can allow to enhance the dissolution up to more than 10 000 times in pH neutral solutions. Studies have shown that ionic oxides such as ZnO tend to have high solubility in ChCl:malonic acid, ChCl:urea and Ethaline, which can resemble the solubilities in aqueous acidic solutions, e.g., HCl. Covalent oxides such as TiO2, however, exhibits almost no solubility. The electrochemical dissolution of metal oxides is strongly dependent on the proton activity from the HBD, i.e. capability of the protons to act as oxygen acceptors, and on the temperature. It has been reported that eutectic ionic fluids of lower pH-values, such as ChCl:oxalic acid and ChCl:lactic acid, allow a better solubility than that of higher pH (e.g., ChCl:acetic acid). Hence, different solubilities can be obtained by using, for instance, different carboxylic acids as HBD.


Outlook

Currently, the stability of most ionic liquids under practical electrochemical conditions is unknown, and the fundamental choice of ionic fluid is still empirical as there is almost no data on metal ion thermodynamics to feed into solubility and speciation models. Also, there are no Pourbaix diagrams available, no standard redox potentials, and bare knowledge of speciation or pH-values. It must be noticed that most processes reported in the literature involving ionic fluids have a Technology Readiness Level (TRL) 3 (experimental proof-of-concept) or 4 (technology validated in the lab), which is a disadvantage for short-term implementation. However, ionometallurgy has the potential to effectively recover metals in a more selective and sustainable way, as it considers environmentally benign solvents, reduction of greenhouse gas emissions and avoidance of corrosive and harmful reagents.


References


Further reading

* Gilchrist, J.D. (1989). ''Extraction Metallurgy'', Pergamon Press. * Mailoo Selvaratnam, (1996): ''Guided Approach to Learning Chemistry''. {{Extractive metallurgy Metallurgy