EXTRACTION OF AL,ZN,MG

USES OF ALUMINUM


Al is a good conductor of heat and electricity, less

expensive than copper (as a replacement for Cu)
In Aluminum alloys in transport industries and
structural applications(High strength to weight ratio)
In kitchenware, chemical industries, milk processingcorrosion resistance and non toxic
In roofing system and thermal insulation either as
metal foil or paint-high reflectivity and low emissivity

METHODS OF EXTRACTION





Hall-Heroult Process (Electro winning) widely accepted

method
Electro refining
Carbothermic reduction not economical commercially
due to
high temperature requirement, undesirable Aluminum
carbide formation and high cost of refractories
Aqueous solution electrolysis not feasible

BAYERS PROCESS






High purity alumina produced required for electrolysis

Bauxite is leached by NaOH, high pressure-25 atm,
temp-220oC to form soluble sodium aluminate.
Al(OH)3 is subsequently precipitated
Al(OH)3 is calcined to obtain Al2O3

BAYERS PROCESS
Leaching reactions
Al2O3.H2O + 2 NaAlO2 = 2NaAlO2 + 2H2O
Al2O3.3H2O + 2NaOH = 2NaAlO2 + 4H2O

Factors affecting Bayers Process

1. The finer the bauxite, the better the digestion of
alumina in leach liquor
2. Digestion is accelerated at high temperatures(220OC)

BAYERS PROCESS
3. Sensible heat of hot leach liquor after filtration
recovered by heat exchanger
4. Precipitation stage is left incomplete because of
simultaneous precipitation of dissolved silica results
in a product unsuitable for electrolysis

ALUMINUM PLANTS-INDIA
SNO

Plant

Smelter

Deposits

Plant Capacity
(tons/yr)

HINDALCO

Renukut,UP

Amarkantak, MP

95000

MALCO

Mettur,TN

Sheavoroy, Kolli
Hills,TN

21000

INDALCO

Hirakud,OR
Alwaye,KE
Belgaum,KA

Ranchi,BI
Kolhapur,MAH

103000

BALCO

Korba,MP

Amarkantak, MP
Pholkapahar,MP

25000

Ref: Non Ferrous Extractive Metallurgy-HS Ray

USES OF ZINC






Zinc is most extensively used as a protective coating

for steel (galvanizing)
It resists atmospheric corrosion by forming impervious
ZnCO3 layer
Zinc is used in alloys such as brass (Cu-Zn)
Zinc is used in die casting, forging and extrusion
Rolled Zn plates used in dry cell batteries

EXTRACTION-ZINC
Methods of Extraction
 Imperial smelting process- reduction of ZnO by carbon
 Hydrometallurgical process combined with
 Electrowinning of Zn
 Electro refining of Zn

EXTRACTION- ZINC





Hydrometallurgical Processes have been used for

extraction of Zinc from wide variety of ores
Zinc concentrate is first roasted
Position of Zn high in electrochemical series
For electrolytic recovery of Zinc, it should be free from
impurities like Cd, Pb, Cu, Fe, As and Ge.
They reduce current efficiency during electrolysis

EXTRACTION- ZINC
Steps involved
1. Dissolution of Zinc calcine in sulphuric acid
2. Precipitation of Cd by adding Zn dust to leach
solution -cementation(some Co and Cu are formed)
3. Precipitation of Co from leach solution by adding nitroso -napthol
4. Electrolysis of purified leach solution using a cell with
Pb-Ag anode and aluminum cathode, electrolyte is
Zinc sulphate + Sulphuric acid

ZINC PLANTS-INDIA
SNO Plant

Smelter

Plant Capacity
(tons/yr)

Hindustan
Zinc Limited

Zawar Mines, Debari,

(Udaipur, Rajasthan)

Zn- 45000
Cd-80
H2S04- 90 tons per day
Superphosphate-220
tons per day

Hindustan
Zinc Limited

Visakhapatnam, AP

Zn- 30000

COMINCOBINANI

Alwaye, Kerala

Zn-20000

USES OF MAGNESIUM


Alloying-widely used in aluminum base alloys to impart

hardness, strength and corrosion resistance
Used to deoxidize and desulphurize molten metals
(magnesium has strong affinity for oxygen)
Mg can nodulize graphite particles in cast iron
(spheroid graphite iron )
(S.G.Iron) stronger, tougher and more ductile than
ordinary iron

USES OF MAGNESIUM


When ignited, Mg emits a brilliant light. This property

is extensively applied in fireworks and photography
Flashlight powder consists of magnesium powder
mixed with chemicals
Alloys of Mg and Al used in aircraft industry for light
weight, machinability, rigidity, resistant to chemical
corrosion

EXTRACTION- MAGNESIUM
Methods of extraction
1. MgO(c) + C(c) = Mg(g) + CO(g)
T=
1800OC
2. MgO(c) + CaC2
CaO + Mg + 2C
T=
1200OC
3. 3MgO(c) + 2Al(l)
Al2O3 + 3Mg(g)
T= 1200OC
4.Pidgeon Process reduction of MgO by ferro silicon in
presence of CaO under vacuum
5. Electrolysis of fused salts that contain MgCl2 obtained
from sea water

PIDGEON PROCESS
2MgO.CaO(c) + FeSi(c)  2Mg(g) + 2CaO.SiO2 (c) + Fe(c)

HO = 112 kcal
GO = 19 kcal
 Calcined Dolomite with powdered ferrosilicon is the
charge
 Reduction carried out under vacuum at 1200OC in
externally heated retort
 Magnesium is the only gaseous product and is
removed from retort

PIDGEON PROCESS
More energy required without CaO
2MgO(c) + Si(c)  2Mg(g) + SiO2
HO = 136 kcal
 Catalyst CaF2 or MgF2


EQUIPMENT AND OPERATION








Retorts are inserted horizontally in a single furnace

(20 per furnace)
Retorts are made of Nichrome steel
Furnace is heated by gas or electricity
Feed calcined dolomite and ferro silicon
Heating is carried out to remove combined water

EQUIPMENT AND OPERATION





Temp. raised to 1150OC and vacuum is connected

Magnesium vaporizes and condenses at the cool end
After 10 hours, vacuum stopped and condensed
magnesium is removed

PIDGEON PROCESS





Initial reaction takes place between ferrosilicon and

Cao to produce a liquid Ca-Si-Fe alloy, which
permeates the charge
This reaction takes place at 1000OC and is mildly
exothermic
This ternary alloy serves as reducing agent
Magnesium vapors are produced by reduction of MgO
by Ca-Si-Fe alloy

DOW PROCESS
MgCl2 + Ca(OH)2 = Mg(OH)2 + CaCl2
MgSO4 + Ca(OH)2 = Mg(OH)2 + CaSO4
 Fused salt electrolysis of MgCl2, CaCl2 and NaCl
 Steel cathode and graphite anodes
 Temp requirement- 670 to 730OC
 Voltage 6.6V and current requirement-30000 to
50000 A

MAGNESIUM PLANTS-INDIA
S
N
O

Plant

Location

Process

Plant
Capacity
(tons/yr)

National
Metallurgical
Laboratory
(NML)

Jamshedpur

-Ferrosilicon reduction of
calcined dolomite

250

Central
Karaikudi, TN
Electrochemical
Research
Institute (CECRI)

-electrolytic reduction of
MgCl2 produced from
magnesite

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