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Smelting is a process of applying heat and a chemical reducing agent to an ore to extract a desired base metal product. [1] It is a form of extractive metallurgy that is used to obtain many metals such as iron , copper , silver , tin , lead and zinc .
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In metallurgy, refining consists of purifying an impure metal. It is to be distinguished from other processes such as smelting and calcining in that those two involve a chemical change to the raw material, whereas in refining the final material is chemically identical to the raw material. Refining thus increases the purity of the raw material ...
In operation, after the bloomery is heated typically with a wood fire, shifting to burning sized charcoal, iron ore and additional charcoal are introduced through the top. Again, traditional methods vary, but normally smaller charges of ore are added at the start of the main smelting sequence, increasing to larger amounts as the smelt progresses.
Induction furnaces do not require an arc, as in an electric arc furnace, or combustion, as in a blast furnace. As a result, the temperature of the charge (the material entered into the furnace for heating, not to be confused with electric charge ) is no higher than required to melt it; this can prevent the loss of valuable alloying elements.
The end products are usually molten metal and slag phases tapped from the bottom, and waste gases exiting from the top of the furnace. [2] The downward flow of the ore along with the flux in contact with an upflow of hot, carbon monoxide -rich combustion gases is a countercurrent exchange and chemical reaction process.
A red-hot metal workpiece is inserted into a forging press. Plastic deformation involves using heat or pressure to make a workpiece more conductive to mechanical force. Historically, this and casting were done by blacksmiths, though today the process has been industrialized. In bulk metal forming, the workpiece is generally heated up. Cold ...
The process used at the Lünen smelter involves charging the furnace with copper residues and scrap containing between 1 and 80% copper and then melting it in a reducing environment. This produces a "black copper phase" and a low-copper silica slag. Initially the black copper was converted to blister copper in the ISASMELT furnace. [57]