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NFMMTA3-Test 1 Memo Ok

The document outlines a test memo for the Non-Ferrous Metallurgy subject in the Bachelor of Engineering Technology program, detailing two questions related to extraction metallurgy processes. It covers the Hall-Héroult process and the three layers process for aluminum extraction, as well as calculations for roasted product weight, proximate analysis, unroasted sulfur percentage, and theoretical air volume for roasting. The test is facilitated by Mr. Craig Nsakabwebwe and is scheduled for April 9, 2024.

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40 views3 pages

NFMMTA3-Test 1 Memo Ok

The document outlines a test memo for the Non-Ferrous Metallurgy subject in the Bachelor of Engineering Technology program, detailing two questions related to extraction metallurgy processes. It covers the Hall-Héroult process and the three layers process for aluminum extraction, as well as calculations for roasted product weight, proximate analysis, unroasted sulfur percentage, and theoretical air volume for roasting. The test is facilitated by Mr. Craig Nsakabwebwe and is scheduled for April 9, 2024.

Uploaded by

pfukanisibuyi7
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

PROGRAM : BACHELOR OF ENGINEERING TECHNOLOGY

EXTRACTION METALLURGY

SUBJECT : NON-FERROUS METALLURGY

CODE : NFMMTA3

TEST1- MEMO

MODULE FACILITATOR : Mr. CRAIG NSAKABWEBWE

DATE : Monday 9 /04/2024

DURATION : 60 min

TIME : 9h40-11h40

TOTAL MARKS : 30

INSTRUCTIONS : ANSWER ALL THE 2 QUESTIONS.


Question 1.1. Hall-Heroult process (5marks)

In the Hall-Héroult process alumina, Al2O3 is dissolved in a carbon-lined bath of


molten cryolite, Na3AlF6. Aluminium fluoride, AlF3 is also present to reduce the melting point
of the cryolite. The mixture is electrolyzed, which reduces the liquid aluminium. This causes
the liquid aluminium to be deposited at the cathode as a precipitate. The carbon anode is
oxidized and bubbles away as carbon dioxide. The overall chemical reaction is:

2 Al2O3 + 3 C → 4 Al + 3 CO2

The liquid aluminium product is denser than the molten cryolite and sinks to the bottom of the
bath, where it is periodically collected

Question 1.2. Three layers process (5marks)


In the three layers process, the graphite electrode is used as cathode and carbon bottom acts as
anode. Electrolytic refining takes place in a cell in which the anode is at the bottom, the current
travelling up through the bath and being collected at the top by graphite. A dense electrolyte
(which consists of 36% aluminium fluoride, 30% cryolite, 18% barium fluoride, and 16%
calcium fluoride) forms the middle layer (density is 2800 kg/m3). The impure metal is alloyed
with copper (28–30% Cu), and this heavy alloy (density is 4500 kg/m3) forms the bottom layer.
The purified aluminium (99.99%, density is 2300 kg/m3) is floated upward during electrolysis
to form the top layer.
Question 2a. Determination of the weight of the roasted product (6 marks)
Weight of the roasted product = Weight(Fe2 O3 + PbSO4 + PbS + PbO + CaO + SiO2 )
PbS = 31.55kg
PbSO4 = 14.86kg
PbO = 37.15kg
Fe2 O3 = 6.19kg
SiO2 = 6kg
CaO = 2.24kg
Weight of the roasted product = 6.19 + 14.86 + 37.15 + 2.24 + 31.55 + 6 = 97.99 kg
Question 2b. Proximate analysis(6marks)
31.55 ∗ 100
PbS = = 32.2%
97.99
14.86 ∗ 100
PbSO4 = = 15.16%
97.99
37.15 ∗ 100
PbO = = 37.9%
97.99
6.19 ∗ 100
Fe2 O3 = = 6.32%
97.99
6 ∗ 100
SiO2 = = 6.12%
97.99
2.24 ∗ 100
CaO = = 2.28%
97.99
Question 2c. Percentage of unroasted sulphur (2marks)
unreacted sulphur ∗ 100
% unroasted sulphur =
sulphur concentrate
Sulphur concentrate = (25.10 + 111.26)kg = 13.64kg
Sulphur unroasted(sulphur remained) = Sulphur PbS(left) + Sulphur PbSO4
Sulphur unroasted = (4.22 + 1.57)kg = 5.79kg
5.79 ∗ 100
% unroasted sulphur = = 42.44%
13.64
Question 2c. Theoretical volume of air for both roasting and reaction stages(6marks)
PbS + 1.5O2 → PbO + SO2 (1)
PbS + 2O2 → PbSO4 (2)
2FeS + 3.5O2 → Fe2 O3 + 2SO2 (3)
Theoretical oxygen mass = oxygen(1) + oxygen(2) + oxygen(3)
Theoretical oxygen mass = kg(8.15 + 3.14 + 4.39) = 15.68kg
15.68
nO2 = = 0.49 kgmoles
32
Theoretical volume of oxygen = 0.49 ∗ 22.4 = 10.98 m3 O2
10.98 ∗ 100
Theoretical volume of air = = 52.28m3
21

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