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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 .
The tatara (鑪) is a traditional Japanese furnace used for smelting iron and steel. The word later also came to mean the entire building housing the furnace. The traditional steel in Japan comes from ironsand processed in a special way, called the tatara system. [1] Iron ore was used in the first steel manufacturing in Japan.
Smelting involves thermal reactions in which at least one product is a molten phase. Metal oxides can then be smelted by heating with coke or charcoal (forms of carbon), a reducing agent that liberates the oxygen as carbon dioxide leaving a refined mineral.
Zinc smelting has historically been more difficult than the smelting of other metals, e.g. iron, because in contrast, zinc has a low boiling point. At temperatures typically used for smelting metals, zinc is a gas that will escape from a furnace with the flue gas and be lost, unless specific measures are taken to prevent it.
The metal ore is either distilled in an electrolyte or acid solution, then magnetically deposited onto a cathode plate (electrowinning); or smelted then melted using an electric arc or plasma arc furnace (electrothermic reactor). [7] Another major difference in non-ferrous extraction is the greater emphasis on minimizing metal losses in slag.
One important furnace application, especially in iron and steel production, is smelting, where metal ores are reduced under high heat to separate the metal content from mineral gangue. The heat energy to fuel a furnace may be supplied directly by fuel combustion or by electricity. Different processes and the unique properties of specific metals ...
Charcoal is nearly pure carbon, which, when burned, both produces the high temperature needed for the smelting process and provides the carbon monoxide needed for reduction of the metal. The ore is broken into small pieces and usually roasted in a fire, to make rock-based ores easier to break up, bake out some impurities, and (to a lesser ...
The smelting of copper, lead and bauxite in non-ferrous smelting, for instance, is designed to remove the iron and silica that often occurs with those ores, and separates them as iron-silicate-based slags. [1] Copper slag, the waste product of smelting copper ores, was studied in an abandoned Penn Mine in California, US.
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