ABOUT THE COURSE: Basic principles involved in processing of minerals, extraction and refining of metals will be covered in this course to reflect the developments in the technology and science in extractive metallurgy. Unit process based approach will be followed instead of current practice of descriptive presentation on a metal-by-metal basis. Emphasis will be given to the understanding of the basic philosophy behind the unit processes, their application in the overall extraction flow-chart for extraction to a specific set of metals based on their ore type, association impurity in are and refining criteria.INTENDED AUDIENCE: Undergraduate (both Major and Minor) students of Metallurgical Engineering, Metallurgy and Materials Science, Materials Engineering and Process Metallurgy, Chemical Engineering PREREQUISITES: Higher Secondary level Chemistry, Mathematics and Thermodynamics INDUSTRY SUPPORT: Aluminium Extraction Industries (e.g., Vedanta Aluminium, National Aluminium Company Limited (NALCO), Bharat Aluminium Company Limited (BALCO), Hindalco Aluminium etc); Copper Extraction Industries (e.g., Hindustan Copper Ltd., Bhagyanagar India Ltd. etc); Zinc, Lead, Silver, Cadmium Extraction Industries (e.g., Hindustan Zinc Ltd., Ambuja Zinc Ltd. Etc); Titanium and Rare Earth Producers (Indian Rare Earths Limited, Kerala Minerals and Metals Ltd. etc)

Syllabus

Week 1: Classification of Metals, Import Uses of Metals, Overview of the Routes of Metal extraction and Refining
Week 2:Types and Occurrence of Metal bearing Minerals, Mineral Beneficiation Process: Unit Steps, Evaluation of Mineral Beneficiation Operation
Week 3:Unit Processes for Physical Separation of Minerals: Crushing and Grinding (Liberation), Screening and Classification, Solid-Liquid Separation, Automated Sorting
Week 4:Unit Processes for Physical Concentration of Minerals: Gravity Separation, Magnetic Separation, Electrostatic Separation, Froth Flotation
Week 5:Classification and Use of Fuels in Metallurgical Processes, Characterization of Fuels, Coke-Making, Flame Temperature Calculation
Week 6:Types of Metallurgical Furnaces, Fuel Utilization in Furnaces, Heat Exchanger, Furnace Refractories, Agglomeration of ore
Week 7:Unit Processes for Chemical Treatment of Ores: Calcination, Roasting, Thermodynamics of Roasting: Predominant Area Diagram (PDA)
Week 8:Unit Process for Reduction: Smelting, Thermodynamics of Reduction, Application in Iron, Zinc, Lead, Tin, Mg extraction
Week 9:Unit Process for Extraction from Sulfides: Matte Smelting, Conversion, Application to Copper and Nickel Extraction, Flash Smelting, Continuous Conversion
Week 10:Unit Process for Halide-metallurgy and Refining: Kroll Process; Refining of Lead, Iron, Copper, Titanium, Uranium, Silicon; New Methods of Extraction and Refining
Week 11:Unit Process in Hydrometallurgy: Leaching, solvent extraction, ion-exchange, adsorption on charcoal, reduction of ions in solutions, application in Gold, Nickel, Alumina
Week 12:Unit Process in Electrometallurgy: Electrolytic Cell Reduction and Refining, Application in Aluminum; Environmental Concern and Sustainable Metal Extraction