Slag, roasting

In the blast furnace reduction slag-making materials are also added together with a small amount of iron, the function of which is to reduce any sulphide which remains, to the product of the roasting operation to produce a sinter. The sinter is then reduced with coke in a vertical shaft blast furnace in which air is blown tluough tuyeres at the bottom of tire shaft. The temperature in the heartlr where metal is produced must be controlled to avoid the vaporization of any zinc oxide in the sinter. The products of tlris process are normally quite complex, and can be separated into four phases. Typical compositions of these are shown in Table 13.1. 

The production of copper from sulphide minerals is accomplished with a preliminary partial roast of die sulphides before reaction widr air in the liquid state, known as mattes, to form copper metal (conversion). The principal sources of copper are minerals such as chalcopyrite, CuFeSa and bornite CuaFeSa, and hence the conversion process must accomplish the preferential oxidation of non, in the form of FeO, before the copper metal appears. As mentioned before, tire FeO-SiOa liquid system is practically Raoultian, and so it is relatively easy to calculate the amount of iron oxidation which can be canned out to form this liquid slag as a function of the FeO/SiOa ratio before copper oxidation occurs. The liquid slag has a maximum mole fraction of FeO at the matte blowing temperatures of about 0.3, at solid silica saturation. 

The usual extraction procedure is to roast the crushed ore, or vanadium residue, with NaCl or Na2C03 at 850°C. This produces sodium vanadate, NaV03, which is leached out with water. Acidification with sulfuric acid to pH 2-3 precipitates red cake , a polyvanadate which, on fusing at 700°C, gives a black, technical grade vanadium pentoxide. Reduction is then necessary to obtain the metal, but, since about 80% of vanadium produced is used as an additive to steel, it is usual to effect the reduction in an electric furnace in the presence of iron or iron ore to produce ferrovanadium, which can then be used without further refinement. Carbon was formerly used as the reductant, but it is difficult to avoid the formation of an intractable carbide, and so it has been superseded by aluminium or, more commonly, ferrosilicon (p. 330) in which case lime is also added to remove the silica as a slag of calcium silicate. If pure vanadium metal is required it can... 

The production of cobalt is usually subsidiary to that of copper or nickel and the methods employed differ widely, depending on which of these it is associated with. In general the ore is subjected to appropriate roasting treatment so as to remove gangue material as a slag and produce a speiss of mixed metal and oxides. In the case of arsenical ores, AS2O6 is condensed and provides a valuable byproduct. In the case of copper ores, the primary process... 

Gar-rdsten, n. (Metal.) finishing roast, -schsum, m. (iron) kish. -scheibe, /. (Copper) disk of refined copper, -schlacke, /. refining slag, rich slag. 

Rdst-schlacke, /. slag from roasting, -schmel-zen, n. (Metal.) roasting and smelting. Rostschutz, m. protection against rust, rust prevention. 

Sinter-ofen, m. sintering furnace, -prozess, m. (Metal.) slag process, -quarz, m. siliceous sin ter. -r dstung, /. sinter roasting, -schlacke, /. clinker, -stein, m. sinter brick. 

The following hypotheses was tested in the first approximation if the vaporization of volatile oxides, sulfides, and metals of all the considered chemical elements at roasting and/or conversion temperature plays a significant role in the contamination of Karabash atmosphere, their calculated equilibrium pressure over the Cu-concentrate, slag, matte or copper melt (or their chemical composition) should strongly correlate with the detected abundance of these elements in snow samples. If such a significant correlation is detected, the corresponding process exerts primary... 

Then the roasted ore is combined with sand, powdered limestone, and some unroasted ore (containing copper(II) sulfide), and heated at 1,100°C in a reverberatory furnace. Copper(II) sulfide is reduced to copper(I) sulfide. Calcium carbonate and silica react at this temperature to form calcium silicate, CaSiOs The liquid melt of CaSiOs dissolves iron(II) oxide forming a molten slag of mixed silicate ... 

The lead concentrate must he roasted for effective removal of sulfur and then smelted in a blast furnace. Sulfur is mostly removed hy a sinter process. The galena concentrate or the ore itself, if its impurity content is low, is mixed with silica and other slag-forming reagents and roasted in sinter machines to produce lead oxide, lead silicate, and some metallic lead. The principal reactions are ... 

C. Extraction. The major industrial source of In is in flue deposits, slags, and residues of the roasting and smelting of Zn and Pb ores. These materials have become concentrated in the element. They are leached with very dilute H2SO4 or HCl to put Zn+ in solution, leaving In203 in the residue. The residue is dissolved in stronger acid, and heavy metals are precipitated out as the sulfides. 

Matte smelting involves roasting the concentrate with lime and recycled converter slag at about 1300 °C to form a slag of molten oxides of iron, silicon, and other impurities, and an immiscible matte or molten sulfide layer, which contains CU2S along with some FeS. 

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