Extractive Metallurgy Course

Lesson 1 • Thermodynamic Principles in Metallurgy

Covers Gibbs free energy, enthalpy, and entropy as applied to metal-oxide and metal-sulfide systems. Provides the thermodynamic basis for reduction reactions.

Lesson 2 • Kinetics of Metallurgical Reactions

Explains rate-controlling steps, activation energy, and mass transfer in heterogeneous systems. Links kinetic theory to reactor and furnace design choices.

Lesson 3 • Introduction to Metals and Ores

Defines metallic minerals, ore grades, and gangue. Establishes vocabulary used throughout all subsequent processing stages.

Lesson 4 • Phase Diagrams and Slag Chemistry

Interprets binary and ternary phase diagrams relevant to smelting. Introduces slag composition, basicity, and its role in metal-slag separation.

Lesson 1 • Energy Efficiency in Comminution

Analyses energy consumption models and identifies inefficiencies in crushing and grinding circuits. Guides circuit optimisation to reduce specific energy consumption.

Lesson 2 • Grinding Mills and Media

Examines ball, rod, SAG, and autogenous mills with respect to charge dynamics and product size. Connects grinding efficiency to downstream liberation.

Lesson 3 • Liberation Analysis and Mineralogy

Introduces automated mineralogy tools to quantify mineral liberation at target grind sizes. Links liberation data to concentration process selection.

Lesson 4 • Crushing Principles and Equipment

Covers jaw, gyratory, and cone crushers, including force mechanics and reduction ratios. Establishes the first stage of ore preparation for all extraction routes.

Lesson 1 • Magnetic and Electrostatic Separation

Examines low- and high-intensity magnetic separators and electrostatic drum separators. Applies to iron ore, ilmenite, and mineral sand processing.

Lesson 2 • Dewatering and Solid-Liquid Separation

Covers thickening, filtration, and drying as final steps in concentration circuits. Prepares concentrate for transport or downstream metallurgical treatment.

Lesson 3 • Flotation Circuit Design and Reagents

Covers rougher, scavenger, and cleaner circuit configurations and reagent dosing strategies. Connects circuit layout to grade-recovery trade-offs.

Lesson 4 • Froth Flotation Fundamentals

Explains surface chemistry, collector adsorption, and bubble-particle attachment. Establishes the physicochemical basis for selective mineral flotation.

Lesson 1 • Roasting Principles and Objectives

Explains oxidative, sulfating, and chloridising roasting to convert sulphides and carbonates. Connects roasting products to subsequent leaching or smelting requirements.

Lesson 2 • Flash and Reverberatory Smelting

Examines flash smelting for copper and nickel concentrates and reverberatory furnace limitations. Highlights autogenous heat balance and environmental advantages of flash smelting.

Lesson 3 • Smelting Thermodynamics and Reactions

Analyses reduction and matte-forming reactions using Ellingham diagrams and activity models. Provides the thermodynamic foundation for furnace charge design.

Lesson 4 • Blast Furnace and Electric Arc Furnace

Covers blast furnace ironmaking and electric arc furnace steelmaking as primary smelting platforms. Compares energy sources, reductants, and productivity metrics.

Lesson 1 • Precious Metal Recovery and Refining

Covers anode slime processing, Miller chlorination, and Wohlwill electrorefining for gold and silver. Establishes purity targets and loss minimisation strategies.

Lesson 2 • Copper Converting: Peirce-Smith Process

Details the two-stage Peirce-Smith converter operation from matte to blister copper. Analyses slag formation, air injection, and heat balance in each stage.

Lesson 3 • Alloying Principles and Melt Treatment

Explains alloying element additions, melt degassing, and inclusion removal for wrought and cast products. Connects melt cleanliness to final mechanical properties.

Lesson 4 • Fire Refining and Anode Casting

Covers oxidation and poling steps to remove sulphur and oxygen from blister copper. Connects anode quality to subsequent electrorefining efficiency.

Lesson 1 • Solvent Extraction Principles

Explains extractant chemistry, McCabe-Thiele diagrams, and mixer-settler design for selective metal transfer. Connects organic phase management to solution purity targets.

Lesson 2 • Leaching Chemistry and Reagents

Covers acid, alkaline, and cyanide leaching mechanisms with Eh-pH (Pourbaix) diagram analysis. Establishes reagent selection criteria for target metal dissolution.

Lesson 3 • Solution Purification and Impurity Removal

Examines cementation, precipitation, and neutralisation to remove impurity metals from pregnant solutions. Prepares purified electrolyte for electrowinning or direct product recovery.

Lesson 4 • Leach Reactor Types and Circuit Design

Compares agitated tank, heap, vat, and in-situ leaching configurations for throughput and recovery. Guides reactor selection based on ore grade, permeability, and capital constraints.

Lesson 1 • Molten Salt Electrolysis for Reactive Metals

Examines electrolytic production of titanium, magnesium, and rare earth metals from molten chloride and fluoride salts. Highlights containment, atmosphere control, and product purity challenges.

Lesson 2 • Copper Electrorefining Cell Design

Details anode-cathode geometry, electrolyte composition, and additive roles in copper electrorefining. Connects cell parameters to cathode purity and anode passivation control.

Lesson 3 • Electrowinning from Leach Solutions

Covers copper, zinc, and cobalt electrowinning from sulfate electrolytes using insoluble anodes. Analyses current density, temperature, and additive effects on deposit morphology.

Lesson 4 • Electrochemical Fundamentals

Reviews Faraday's laws, electrode potentials, and overpotential concepts as applied to metal deposition. Provides the electrochemical basis for cell design and current efficiency.

Lesson 1 • Techno-Economic Evaluation of Flowsheets

Covers capital and operating cost estimation, net present value analysis, and sensitivity studies for metallurgical projects. Enables comparison of competing flowsheet options on economic merit.

Lesson 2 • Metallurgical Accounting and Sampling

Covers sampling theory, assay methods, and metal accounting systems for production reporting. Connects accurate accounting to process control and commercial settlement.

Lesson 3 • Energy and Water Integration

Applies pinch analysis and water circuit design to minimise energy and freshwater consumption. Demonstrates how integration reduces operating costs and environmental footprint.

Lesson 4 • Process Control and Instrumentation

Introduces sensors, control loops, and advanced process control strategies for metallurgical plants. Links real-time data to operational decisions and grade-recovery optimisation.