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Electric phosphate smelting furnace in a TVA chemical plant (1942) 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.
A water jacket furnace can be used to reduce non-ferrous oxide ores mixed with coke, to produce metal and slag. When smelting lead, the feedstock is lead oxide, coke and fluxes. When smelting lead sulphide ores, the ore is first sintered to form a lead oxide sinter. Lead and silver ores often occur in the same ore body.
A metallurgical furnace, often simply referred to as a furnace when the context is known, is an industrial furnace used to heat, melt, or otherwise process metals. Furnaces have been a central piece of equipment throughout the history of metallurgy ; processing metals with heat is even its own engineering specialty known as pyrometallurgy .
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 Kaldo type converted is commonly known as a Top-Blown Rotary Converter (TBRC) in non-ferrous metal smelting terminology. [16] By the 1970s, the Kaldo furnace was in common use for copper and nickel smelting. [17] A Kaldo converter for the smelting of lead was constructed by Boliden AB in Sweden in 1976. [17]
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A bloomery is a type of metallurgical furnace once used widely for smelting iron from its oxides. The bloomery was the earliest form of smelter capable of smelting iron. Bloomeries produce a porous mass of iron and slag called a bloom .