Extractive metallurgyExtractive metallurgy is a branch of metallurgical engineering wherein process and methods of extraction of metals from their natural mineral deposits 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 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.
Iron oreIron ores are rocks and minerals from which metallic iron can be economically extracted. The ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, or deep purple to rusty red. The iron is usually found in the form of magnetite (Fe3O4, 72.4% Fe), hematite (Fe2O3, 69.9% Fe), goethite (FeO(OH), 62.9% Fe), limonite (FeO(OH)·n(H2O), 55% Fe) or siderite (FeCO3, 48.2% Fe). Ores containing very high quantities of hematite or magnetite, typically greater than about 60% iron, are known as natural ore or direct shipping ore, and can be fed directly into iron-making blast furnaces.
Alkaline earth metalThe alkaline earth metals are six chemical elements in group 2 of the periodic table. They are beryllium (Be), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba), and radium (Ra). The elements have very similar properties: they are all shiny, silvery-white, somewhat reactive metals at standard temperature and pressure. Together with helium, these elements have in common an outer s orbital which is full— that is, this orbital contains its full complement of two electrons, which the alkaline earth metals readily lose to form cations with charge +2, and an oxidation state of +2.
Stainless steelStainless steel, also known as inox or corrosion-resistant steel (CRES), is an alloy of iron that is resistant to rusting and corrosion. It contains at least 10.5% chromium and usually nickel, and may also contain other elements, such as carbon, to obtain the desired properties. Stainless steel's resistance to corrosion results from the chromium, which forms a passive film that can protect the material and self-heal in the presence of oxygen. The alloy's properties, such as luster and resistance to corrosion, are useful in many applications.
Recrystallization (metallurgy)In materials science, recrystallization is a process by which deformed grains are replaced by a new set of defect-free grains that nucleate and grow until the original grains have been entirely consumed. Recrystallization is usually accompanied by a reduction in the strength and hardness of a material and a simultaneous increase in the ductility. Thus, the process may be introduced as a deliberate step in metals processing or may be an undesirable byproduct of another processing step.
CupellationCupellation is a refining process in metallurgy in which ores or alloyed metals are treated under very high temperatures and subjected to controlled operations to separate noble metals, like gold and silver, from base metals, like lead, copper, zinc, arsenic, antimony, or bismuth, present in the ore. The process is based on the principle that precious metals do not oxidise or react chemically, unlike base metals. When they are heated at high temperatures, the precious metals remain apart, and the others react, forming slags or other compounds.
SteelmakingSteelmaking is the process of producing steel from iron ore and/or scrap. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon (the most important impurity) are removed from the sourced iron, and alloying elements such as manganese, nickel, chromium, carbon and vanadium are added to produce different grades of steel. Steelmaking has existed for millennia, but it was not commercialized on a massive scale until the mid-19th century. An ancient process of steelmaking was the crucible process.
Hydrogen productionHydrogen production is the family of industrial methods for generating hydrogen gas. As of 2020, the majority of hydrogen (~95%) is produced from fossil fuels by steam reforming of natural gas and other light hydrocarbons, partial oxidation of heavier hydrocarbons, and coal gasification. Other methods of hydrogen production include biomass gasification, methane pyrolysis, and electrolysis of water. Methane pyrolysis and water electrolysis can use any source of electricity including solar power.
Basic oxygen steelmakingBasic oxygen steelmaking (BOS, BOP, BOF, or OSM), also known as Linz-Donawitz steelmaking or the oxygen converter process, is a method of primary steelmaking in which carbon-rich molten pig iron is made into steel. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and changes it into low-carbon steel. The process is known as basic because fluxes of burnt lime or dolomite, which are chemical bases, are added to promote the removal of impurities and protect the lining of the converter.
Steel millA steel mill or steelworks is an industrial plant for the manufacture of steel. It may be an integrated steel works carrying out all steps of steelmaking from smelting iron ore to rolled product, but may also be a plant where steel semi-finished casting products are made from molten pig iron or from scrap. Since the invention of the Bessemer process, steel mills have replaced ironworks, based on puddling or fining methods. New ways to produce steel appeared later: from scrap melted in an electric arc furnace and, more recently, from direct reduced iron processes.
Hydrogen infrastructureA hydrogen infrastructure is the infrastructure of hydrogen pipeline transport, points of hydrogen production and hydrogen stations (sometimes clustered as a hydrogen highway) for distribution as well as the sale of hydrogen fuel, and thus a crucial prerequisite before a successful commercialization of automotive fuel cell technology. A hydrogen highway is a chain of hydrogen-equipped filling stations and other infrastructure along a road or highway which allow hydrogen vehicles to travel.
Hydrogen economyThe hydrogen economy uses hydrogen to decarbonize economic sectors which are hard to electrify, essentially, the "hard-to-abate" sectors such as cement, steel, long-haul transport, etc. In order to phase out fossil fuels and limit climate change, hydrogen can be created from water using renewable sources such as wind and solar, and its combustion only releases water vapor into the atmosphere. Although with a very low volumetric energy density hydrogen is an energetic fuel, frequently used as rocket fuel, but numerous technical challenges prevent the creation of a large-scale hydrogen economy.
Mineral processingIn the field of extractive metallurgy, mineral processing is the process of separating commercially valuable minerals from their ores. Depending on the processes used in each instance, it is often also known as ore dressing or ore milling. Before the advent of heavy machinery the raw ore was broken up using hammers wielded by hand, a process called "spalling". Before long, mechanical means were found to achieve this. For instance, stamp mills were used in Samarkand as early as 973. They were also in use in medieval Persia.
Pig ironPig iron, also known as crude iron, is an intermediate good used by the iron industry in the production of steel, which is developed by smelting iron ore in a blast furnace. Pig iron has a high carbon content, typically 3.8–4.7%, along with silica and other constituents of dross, which makes it brittle and not useful directly as a material except for limited applications. The traditional shape of the molds used for pig iron ingots is a branching structure formed in sand, with many individual ingots at right angles to a central channel or "runner", resembling a litter of piglets being nursed by a sow.
Metal toxicityMetal toxicity or metal poisoning is the toxic effect of certain metals in certain forms and doses on life. Some metals are toxic when they form poisonous soluble compounds. Certain metals have no biological role, i.e. are not essential minerals, or are toxic when in a certain form. In the case of lead, any measurable amount may have negative health effects. It is often thought that only heavy metals can be toxic, but lighter metals such as beryllium and lithium may also be in certain circumstances.
BiohydrogenBiohydrogen is H2 that is produced biologically. Interest is high in this technology because H2 is a clean fuel and can be readily produced from certain kinds of biomass, including biological waste. Furthermore some photosynthetic microorganisms are capable to produce H2 directly from water splitting using light as energy source. Besides the promising possibilities of biological hydrogen production, many challenges characterize this technology. First challenges include those intrinsic to H2, such as storage and transportation of an explosive noncondensible gas.
Ladle (metallurgy)In metallurgy, a ladle is a bucket-shaped container or vessel used to transport and pour out molten metals. Ladles are often used in foundries and range in size from small hand carried vessels that resemble a kitchen ladle and hold to large steelmill ladles that hold up to . Many non-ferrous foundries also use ceramic crucibles for transporting and pouring molten metal and will also refer to these as ladles. The basic term is often prefixed to define the actual purpose of the ladle.
Ductile ironDuctile iron, also known as ductile cast iron, nodular cast iron, spheroidal graphite iron, spheroidal graphite cast iron and SG iron, is a type of graphite-rich cast iron discovered in 1943 by Keith Millis. While most varieties of cast iron are weak in tension and brittle, ductile iron has much more impact and fatigue resistance, due to its nodular graphite inclusions. On October 25, 1949, Keith Dwight Millis, Albert Paul Gagnebin and Norman Boden Pilling received US patent 2,485,760 on a cast ferrous alloy for ductile iron production via magnesium treatment.
Hydrogen vehicleA hydrogen vehicle is a vehicle that uses hydrogen fuel for motive power. Hydrogen vehicles include hydrogen-fueled space rockets, as well as ships and aircraft. Power is generated by converting the chemical energy of hydrogen to mechanical energy, either by reacting hydrogen with oxygen in a fuel cell to power electric motors or, less commonly, by burning hydrogen in an internal combustion engine. there are two models of hydrogen cars publicly available in select markets: the Toyota Mirai (2014–), which is the world's first mass-produced dedicated fuel cell electric vehicle (FCEV), and the Hyundai Nexo (2018–).
Crucible steelCrucible steel is steel made by melting pig iron (cast iron), iron, and sometimes steel, often along with sand, glass, ashes, and other fluxes, in a crucible. In ancient times steel and iron were impossible to melt using charcoal or coal fires, which could not produce temperatures high enough. However, pig iron, having a higher carbon content and thus a lower melting point, could be melted, and by soaking wrought iron or steel in the liquid pig-iron for a long time, the carbon content of the pig iron could be reduced as it slowly diffused into the iron, turning both into steel.
