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Smelting is a process of applying heat to an 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 chemical- reducing agent to decompose the ore, driving off other elements as gases or slag and leaving the metal base behind. The reducing agent is commonly a fossil fuel source of carbon, such as coke—or, in earlier times, charcoal. The oxygen in the ore binds to carbon at high temperatures as the chemical potential energy of the bonds in carbon dioxide is lower than the bonds in the ore.
A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. Blast refers to the combustion air being supplied above atmospheric pressure.
Dudd (Dud) Dudley (1600–1684) was an English metallurgist, who fought on the Royalist side in the English Civil War as a soldier, military engineer, and supplier of munitions. He was one of the first Englishmen to smelt iron ore using coke.
Metallum Martis, a 1665 book by Dud Dudley, is the earliest known reference to the use of coal in metallurgical smelting. The book is also referred to as Iron made with Pit-Coale, Sea-Coale, &c. And with the same Fuell to Melt and Fine Imperfect Mettals, And Refine perfect Mettals.
Edward Sutton, 5th Baron Dudley was an English peer, politician and landowner who briefly sat in the House of Commons. Through his intemperate behaviour he won widespread notoriety, completed the financial ruin of his family, and was the last of his name to bear the title.
Copper extraction refers to the methods used to obtain copper from its ores. The conversion of copper ores consists of a series of physical, chemical and electrochemical processes. Methods have evolved and vary with country depending on the ore source, local environmental regulations, and other factors.
Coalbrookdale is a village in the Ironbridge Gorge in Shropshire, England, containing a settlement of great significance in the history of iron ore smelting. It lies within the civil parish called the Gorge.
A reverberatory furnace is a metallurgical or process furnace that isolates the material being processed from contact with the fuel, but not from contact with combustion gases. The term reverberation is used here in a generic sense of rebounding or reflecting, not in the acoustic sense of echoing.
An ironworks or iron works is an industrial plant where iron is smelted and where heavy iron and steel products are made. The term is both singular and plural, i.e. the singular of ironworks is ironworks.
Abraham Darby, in his later life called Abraham Darby the Elder, now sometimes known for convenience as Abraham Darby I, was a British ironmaster and foundryman. Born into an English Quaker family that played an important role in the Industrial Revolution, Darby developed a method of producing pig iron in a blast furnace fuelled by coke rather than charcoal. This was a major step forward in the production of iron as a raw material for the Industrial Revolution.
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.
The London Lead Company was an 18th and 19th century British lead mining company. It was incorporated by royal charter. Strictly, it was The Company for Smelting Down Lead with Pitcoal.
Ferrous metallurgy is the metallurgy of iron and its alloys. The earliest surviving prehistoric iron artifacts, from the 4th millennium BC in Egypt, were made from meteoritic iron-nickel. It is not known when or where the smelting of iron from ores began, but by the end of the 2nd millennium BC iron was being produced from iron ores in the region from Greece to India, and sub-Saharan Africa. The use of wrought iron was known by the 1st millennium BC, and its spread defined the Iron Age. During the medieval period, smiths in Europe found a way of producing wrought iron from cast iron using finery forges. All these processes required charcoal as fuel.
Mount Isa Mines Limited ("MIM") operates the Mount Isa copper, lead, zinc and silver mines near Mount Isa, Queensland, Australia as part of the Glencore group of companies. For a brief period in 1980, MIM was Australia's largest company. It has pioneered several significant mining industry innovations, including the Isa Process copper refining technology, the Isasmelt smelting technology, and the IsaMill fine grinding technology, and it also commercialized the Jameson Cell column flotation technology.
Shadrach Fox was the ironmaster who preceded Abraham Darby at Coalbrookdale.
Henry Howard, 5th Earl of Suffolk was the youngest son of Theophilus Howard, 2nd Earl of Suffolk, but inherited the title because none of his brothers left surviving sons.
Plants for the production of lead are generally referred to as lead smelters. Primary lead production begins with sintering. Concentrated lead ore is fed into a sintering machine with iron, silica, limestone fluxes, coke, soda ash, pyrite, zinc, caustics or pollution control particulates. Smelting uses suitable reducing substances that will combine with those oxidizing elements to free the metal. Reduction is the final, high-temperature step in smelting. It is here that the oxide becomes the elemental metal. A reducing environment pulls the final oxygen atoms from the raw metal.
The ISASMELT process is an energy-efficient smelting process that was jointly developed from the 1970s to the 1990s by Mount Isa Mines and the Government of Australia’s CSIRO. It has relatively low capital and operating costs for a smelting process.
The Bottom-blown Oxygen Converter or BBOC is a smelting furnace developed by the staff at Britannia Refined Metals Limited (“BRM”), a British subsidiary of MIM Holdings Limited. The furnace is currently marketed by Glencore Technology. It is a sealed, flat-bottomed furnace mounted on a tilting frame that is used in the recovery of precious metals. A key feature is the use of a shrouded lance to inject oxygen through the bottom of the furnace, directly into the precious metals contained in the furnace, to oxidize base metals or other impurities as part of their removal as slag.
A metallurgical furnace, more commonly referred to as a furnace, is an industrial furnace used to heat and melt metal ore to remove gangue, primarily in iron and steel production. The heat energy to fuel a furnace may be supplied directly by fuel combustion, by electricity such as the electric arc furnace, or through induction heating in induction furnaces. There are several different types of furnaces used in metallurgy to work with specific metal and ores.
References
- ↑ J. Nichols, History and Antiquities of Leicestershire III(1) (1800), 326.
- ↑ King, P. W. (2002). "Dud Dudley's contribution to metallurgy". Historical Metallurgy. 36 (1): 43–53.
- ↑ A. W. Skempton et al., Biographical Dictionary of Civil Engineers I (2002), 808-13.
- ↑ P. W. King, 'The cupola at Bristol' Somerset Archaeol. & Nat. Hist. 140 (1997), 37-51.
- ↑ P. W. King, 'Sir Clement Clerke and the Adoption of Coal in metallurgy' Trans. Newcomen Soc. 73(1) (2001-2), 33-52.