Principles of Roasting and

Its Types

By: AKSHAT
CHATURVEDI
ANITA KASOT
HEENA YADAV
HITESH GUPTA
MUKESH NAINWAL
PRACHI BAFNA

Various Metallurgical
Proceses

Hydrometallurgyisamethodforobtainingmetalsfromtheir
ores.Itisatechniquewithinthefieldofextractive
metallurgyinvolvingtheuseofaqueouschemistryforthe
recoveryofmetalsfromores,concentrates,andrecycledor
residualmaterials
Electrometallurgyisatermusedforprocessesthatrefineor
purifymetalsusingelectricity.Itcanalsobeageneralterm
forelectricalprocessesusedtoplateonemetalwithanother
fordecorativeorcorrosionresistancepurposes.
Pyrometallurgyisabranchofextractivemetallurgy.It
consistsofthethermaltreatmentofmineralsand
metallurgicaloresandconcentratestobringaboutphysical
andchemicaltransformationsinthematerialstoenable
recoveryofvaluablemetals

Pyrometallurgy
Pyrometallurgy
Calcination

Pyrometallurgydealswiththeextractionof

mineralsfromorebytreatingthemwithheat.

ROASTING
Inroasting,theoreisheatedinaregularsupplyofair
inafurnaceatatemperaturebelowthemeltingpoint
ofthemetal.
Roastingisametallurgicalprocessinvolvinggassolid
reactionsatelevatedtemperatureswiththegoalof
purifyingthemetalcomponent(s).
Oftenbeforeroasting,theorehasalreadybeen
partiallypurified,e.g.byfrothfloatation.The
concentrateismixedwithothermaterialstofacilitate
theprocess.
Thisprocessisgenerallyappliedtosulphideminerals.
Duringroasting,thesulfideisconvertedtoanoxide,
andsulfurisreleasedassulfurdioxide,agas.

 FortheoresCu2S(chalcocite)andZnS

(sphalerite),balancedequationsfortheroasting
are: 2Cu2S+3O22Cu2O+2SO2
2ZnS+3O22ZnO+2SO2

PROCESSES
Thereareseveraldifferenttypesofroast,eachone
intendedtoproduceaspecificreactionandtoyielda
roastedproduct(orcalcine)suitablefortheparticular
processingoperationtofollow.Theroasting
proceduresare:
Oxidizing roasts - whichremoveallorpartofthe
sulfurfromsulfidemetalcompounds,replacingthe
sulfideswithoxides.(Thesulfurremovedgoesoff
assulfurdioxidegas.)Oxidizingroastsare
exothermic.
Sulfatizing roasts - whichconvertcertainmetals
fromsulfidestosulfates.Sulfatizingroastsare
exothermic.

Reducing

roasts,whichlowertheoxidestateor
evencompletelyreduceanoxidetoametal.
Reducingroastsareexothermic.
Chloridizing roasts,orchlorination,which
changemetallicoxidestochloridesbyheating
withachlorinesourcesuchaschlorinegas,
hydrochloricacidgas,ammoniumchloride,or
sodiumchloride.Thesereactionsareexothermic.
Volatilizingroasts,whicheliminateeasily
volatilizedoxidesbyconvertingthemtogases.
Calcination,inwhichsolidmaterialisheatedto
driveoffeithercarbondioxideorchemically
combinedwater.Calcinationisanendothermic
reaction.

Roasting

depends on following factors:

1.Time
2.Temperature
3.AvaibilityofO2orair
4.Physicalcondition

Criteria

of selection of roasting process

1.Physicalconditionofproductblastfurnace
smeltingproductshouldcoarseorcellular reverberatory
furnaceproductshouldbefine leachingproduct
shouldbeporous.
2.Chemicalcompositionofproduct
Forcopperretainsomesulphur
ForLead&Zinc-completeeliminationof
sulphur.

ROASTERS
Eachoftheaboveprocessescanbecarriedoutin

specializedroasters.
Thetypesmostcommonlyinusearefluidizedbed,multiple-hearth,flash,chlorinator,rotarykiln,
andsinteringmachine(orblastroaster).

Flash Roasting
Preheatedoreparticlesaremadetofallthrough

bodyofhotairresultingin
Instantaneousoxidationorflashingofcombustible
constituentsoftheore,mainlysulphur
Hencecalledflashroasting
Oreshouldbeoffinesize
Capacityofflashroaster>hearthroaster
Temp.ofcombustionzone=900-9500C

Sinter Roasting/Blast
Roasting
Fineore&concentratehavetobeagglomerated

beforetheycanbechargedinablastfurnace
Treatmentofsulphideoreinasinteringmachine
whereroastingandagglomerationtakeplace
simultaneously
Charge=(fineore+moisture)aslayerof15-50cm
thickonrevolvingbelt
Combustionisdonebyburner
Speedisadjusted-roastingshouldbecompleted
beforeitisdischarged
Produceporouscindercalledsinter
Cooledsinterissizedtogiveuniformproduct

Multiple Hearth
Roasting
Basic principle

Countercurrentflowofsolidore&theoxidizing
gases.

Working:
-Thehearthatthetopdryandheatthecharge

Oreisdischargedautomaticallyatthetophearth

Itgraduallymovesdownwardsthroughalternate
passagesaroundtheshaftandperipheryand
finallyemergesatthebottom

Theoxidizinggasesflowupwards

Externalheatingofchargeisunnecessary
exceptwhenchargecontainmoisture

Drawbacks :
(1)
(2)

Roastingisslow
GasesareunsuitableforproductionofH2SO4
becausetheydonotcontainsufficientSO2andSO3

Pictorial view of multiple hearth roasting unit

Sintering Machine

Fluidized-bedroasting
Principle-Oreparticlesareroasted
whileitissuspendedinan
upwardstreamofgases
-Gaspassesthrough
bottomofthebed
-Behahaviourofthebed
dependsonthevelocityof
gas

Fluidized-bedroasting
Theoreparticlesareroastedwhilesuspendedinan

upwardstreamofgas

Finelygroundsulfideconcentratesinsizeoverthe

range0.005to0.05cmindiameterisused

Asinthesuspensionroaster,thereactionratesfor

desulfurizationaremorerapidthanintheolder
multiple-hearthprocesses.

Fluidized-bedroastersoperateunderapressure

slightlylowerthanatmosphericandattemperatures
averaging1000C(1800F).

Inthefluidized-bedprocess,noadditionalfuelis

requiredafterignitionhasbeenachieved.

Steps observed during roasting

process
Stage-1

Whenthegasflowrateisverylow,andtheorebedis
porous,thegaspermeatesthebedwithoutdisturbing
theoreparticles
Pressuredropacrossthebedisproportionaltoflow
rate

Stage-2
Gasvelocityincreses,thebedexpandsupwardsdue
totheeffectofthedragforcesexertedbygasstream
Thepressuredropacrossthebeddependsonthegas
velocity

Stage-3
Whengasvelocityfurtherincreasesastageis

reached
Pressuredrop=wt.oftheparticleperunitareaof
thebed
Particlesremainindividuallysuspendedandoffer
lessresistancetogasflow

Stage-4
Furtherincreaseingasvelocityleadtocontinued

expansionofthebed
Resultsinincreaseininterparticledistance
Pressuredropacrossbedcontinuestodecrease
asthegasvelocityincreases

Stage-5
Finally,theexpansionofthebedisindependentof

gasvelocity
Outcominggasstreamappearsintheformof
bubblesburstingonthesurfaceofthebedwhich
lookslikewellstirredboilingliquid
Inthisconditionthebedissaidtobefluidized.
Thefluidizedbedhasanapparentdensitydistinctly
differentfromthedensityofthesolidandis
capableofflowinglikealiquid.

The Fluidization Behaviour

Advantages
High

energy efficiency because it can

be autogenously operated

Useful

in recovery of sulphur because

the gas that it produces has high SO 2
content

Ideal

for roasting of oxide ores because

the oxidizing reactions that take place
during roasting is highly exothermic.
e.g. Pyrite FeS2, Millerite NiS, etc.

Thank You

Any queries
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