APPLIED CHEMISTRY ASSIGNMENT

Course (CY-110)

TOPIC: “EXTRACTION OF METALS BY

MAGNETIC SEPARATION AND GRAVITY”

Submitted By:
Mashooda Abdullah (EL-012)
Syeda Malaika Zehra (EL-017)
Bismah Imran (EL-018)
Ghazia Mughal (EL-043)
Nimra Mughal (TC-18302)
 EXTRACTION OF METALS

Occurrence of Metals:
Earth’s crust is the storehouse of metals such as sulphur, silicon. Some of the
major metals are also found in seawater such as chloride. They are present in a
free state as well as a combined state. For example, gold and platinum are
available in a free state whereas calcium and copper are available in combined
states. The metals found in the Free State are also called noble metals as they
show the least amount of chemical reactivity. On the other hand, the metal
present in the combined state can easily react. A material that is naturally
occurring comprising the metal is known as a mineral. The pure form of mineral
from which a metal can be extracted is called the ore.

Types of Ores:
Given below are the types of ores with their examples-

1. Oxide Ores-
In this particular ore, the metals are present in the oxidised form. Obtaining
metals from this ore is much easier. For example, Haematite ore ( Iron)
and Bauxite ore (Aluminium)
2. Sulphide Ores-
In this particular ore, the metals are present in the sulphide form. Since it is
difficult to extract metals from this ore, they are usually converted to oxides
with the process of metallurgy. For example, Zinc Blende ( Zinc) and Lead
(Galena)
3. Carbonate Ores-
In this ore, carbonate ions are present. Since it is difficult to extract metals
from these ores, they are also converted to oxide ores first. For example,
Calamine (Zinc)
4. Sulphate Ores-
They are generally found underground and have sulphur ions present in
them. For example, Anglesite (Lead)
Now, there are various steps, such as the concentration of ore, roasting,
calcinations, reduction, electrolysis, and refining that can be involved in the
extraction of metals from their respective ores. Metals with different reactivities
undergo different steps for their extraction, as shown in the Figure below.

1. Grinding and Crushing

The bigger chunks of the ore extracted are crushed and ground in ball mills and
crushers. It helps to increase the surface area of the chunks for better chemical
actions later. In technical terms, it is called pulverization.

2. Concentration of Ores

The very first step, which is the concentration of ore, involves the removal of
gangue particles that can be achieved using gravity separation, froth floatation,
magnetic separation, and leaching processes.
 The gravity separation method is used when gangue particles are lighter
than the ore. This method is generally used for the concentration of oxides
and carbonate ores. The method involves the passing of crushed ore particles
 through a stream of water during which the lighter gangue particles are
washed away.
 The froth floatation method is used to remove gangue particles from sulfide
ores. In this method, the crushed ore and water are added to a tank in which a
frothed, such as pine oil, is added and then air is blown under pressure to
create the froth. The gangue particles will be wetted by water and the metal
comes up with the froth.
 The magnetic separation method is used when either metal or gangue
particles have magnetic properties. In this method, the crushed ore is passed
over conveyor belts with magnetic rollers.
 The leaching method is used to concentrate ores of aluminium, silver, and
gold, etc. In this method, the crushed ore is treated with a solvent that
dissolves the ore leaving behind the impurities.

3. Metal Extraction Processes

Roasting is a process of metallurgy where the ore is converted into its oxide by
heating it in the presence of excess air above its melting point. during roasting,
the non-metallic and moisture impurities in the form of volatile gas are released.
The roasting process contains the solid-gas thermal reaction that includes
reduction, oxidation, chlorination, sulfation, and also pyro hydrolysis.

Calcination is the process mostly used in the oxidation of carbonates, roasting is

a method that can be used for converting the sulphide ores. Calcination is the
process used for the thermal decomposition of any material. It is done by heating
a substance to a higher temperature, below its melting point. This heating at high
temperatures helps to remove volatile substances and also oxidizes any mass of
the substance.

4. Refining of Metals
The impure metal produced in the reduction process needs to be refined in order
to obtain pure metal. One of the refining methods is electrolytic refining in which
a strip of impure metal is made at the anode while pure metal is made at the
cathode. The metal salt solution is used as the electrolyte in this process.
 GRAVITY SEPARATION METHOD

INTRODUCTION:
The gravity separation method, also known as hydraulic washing, is used for
metals that are heavier than the gangue particles. In this method, water is used
to enrich the ore. The ore is passed through a stream that goes upward, pushing
up all the lighter particles mainly comprising impurities, while the metals that are
heavier than the impurities settle down as they cannot be pushed. Before
passing it through the stream, the ore is first crushed into a fine powder form, and
the lighter particles, which are the impure particles, get washed away and
separated from the metals. The gravity separation method is mostly used for
concentrating tin and lead oxide from their ores.
JIG CONCENTRATOR

Different elements settle at different rates. Metal ore has been crushed and
screened to produce particles which are similar in size. Some of these
particles are now liberated pieces of metal, and others are minerals with little
value. We now need to separate these particles in order to collect the metal.
In some cases, all of the
particles can be fed to a
jig concentrator. This
rudimentary piece of
mineral processing
equipment uses pulses
of water to suspend the
particles in water. As the
pulses dissipate, the
particles settle in the
bottom of the jig.
Particles with a higher
specific gravity settle
faster than those with a
lower specific gravity,
effectively separating the
metal so it can be
collected. The remaining
particles are sent to
tailings. If there is a
significant portion of fine metal, the tailings are sent to a high G-force gravity
concentrator like the Falcon SB Concentrator. Gravity concentrators use the
same principles of gravity separation at higher velocities. While conventional
gravity separation happens at one G force, the Falcon SB uses up to 200Gs
to concentrate microscopic particles as small as 20 microns. The same
principles apply, just at a smaller scale. Dense particles will settle first and
light ones after.

MAGNETIC SEPARATION METHOD

INTRODUCTION
This method of concentration can be applied when the gangue and the ore
particles have different magnetic properties. For example, if the ore particles are
magnetic in nature and if the gangue particles are non – magnetic, then a strong
magnet can be brought and the magnetic ore particles can be sucked out from
the powdered ore. The powdered ore is poured over a conveyer belt. One of the
rollers of the belt is made out of magnet. The magnetic roller makes the magnetic
ore particles stick on the belt and these are moved at a distance before they are
collected. The gangue particles, being non – magnetic in nature, do not get
attracted to the roller and fall in a heap below the roller itself. Iron ores like
magnetite, chromite and manganese ore like pyrolusite are concentrated by this
process. Sometimes, a reverse situation may occur: the ore is non magnetic and
the gangue is magnetic. In this case also magnetic separation may be used for
concentration of the non – magnetic ore.

MAGNETIC SEPARATOR

Machines used for Magnetic separation. This is a process in which magnetically

susceptible material is extracted from a mixture using a magnetic force. This
separation technique can be useful in mining iron as it is attracted to a magnet.
Magnetic separation is one of the most reliable ways to remove unwanted ferrous
metals during the processing of raw materials. From recycling plants to food and
pharmaceutical manufacturing, we have the perfect industrial magnet to assist
your operation.
WORKING PRINCIPLE:
All materials possess magnetic properties. Substances that have a greater
permeability than air are classified as paramagnetic; those with a lower
permeability are called diamagnetic. Paramagnetic materials are attracted to a
magnet; diamagnetic substances are repelled. Very strongly paramagnetic
materials can be separated from weakly or nonmagnetic materials by the use of
low-intensity magnetic separators. Minerals such as hematite, limonite, and
garnet are weakly magnetic and can be separated from nonmagnetic by the use
of high-intensity separators. The working principle of magnetic separation is that
materials which is going to be elected bearing the force of magnetic and other
mechanical (such as gravity, centrifugal force, friction, medium resistance, etc.)
together, in the sorting space of the magnetic separator. The magnetic suffered
by mineral grains is related with the size and magnetic of the mineral; non-
magnetic mineral particles mainly by mechanical force. Consequently, magnetic
mineral particles and non-magnetic mineral particles move along different paths
to get separation. In general the magnetic force bore by magnetic particles is
proportional to the strength and gradient of the magnetic field. Such mineral
particles with different magnetic properties can be separated. Therefore, the
magnetic selection is a method based on the differences of permeability between
minerals to achieve separation in the non-uniform magnetic field.

Magnetic Separator Applications:

 Recycling
 Mineral processing and ceramics
 Mining and quarrying
 Food production

CONCLUSION
Ores are present in the form of rocks and form naturally. These ores comprise
metals of different kinds as well as other elements and particles that have no
industrial use. The metal compounds are present in sufficient amounts in the ore,
making them worthwhile to extract for use. However, the ore cannot be used if
the necessary metals are not separated from the gangue particles, which are the
unwanted particles that make it inconvenient for use. The concentration of the
ores varies on the amount of metal and gangue present in the ore, and the
methods used for the concentration of ore depend on the chemical and physical
properties of the ore. There are four basic methods for enhancing the
concentration of the ore, leaching method, gravity separation, froth floatation
method, and electromagnetic separation, all used for extracting different kinds of
metals.