Chemical Metallurgy

1 Bonding and Periodicity 1.1 The Atomic Structure of Elements 1.1.1 The Nucleus 1.1.2 Atomic Spectra 1.2 The Periodic Table of the Elements 1.3 Chemical Bonds 1.3.1 The Ionic Bond (Electrovalency) 1.3.2 The Covalent Bond 1.3.3 The Metallic Bond 1.4 A More Detailed Study of the Periodic Table of the Elements 1.4.1 The s-Block Elements 1.4.2 Transition Elements (d-Block) 1.4.3 The P-Block Elements2 Metallurgical Thermodynamics 2.1 Thermochemistry 2.1.1 Exothermic and Endothermic Reactions 2.1.2 Calculating Enthalpies and Enthalpy Change 2.1.3 Measurements of Enthalpy Changes of reactions 2.1.4 Enthalpy Changes: The Effect of Temperature 2.2 Thermodynamics 2.2.1 Energy: The Driving Force for Chemical Change 2.2.2 Free Energy: The Driving Force of a Chemical Reaction 2.2.3 Chemical Equilibrium3 Reaction Kinetics 3.1 Rate of Reaction 3.1.1 Effect of Conditions on Rate of Reaction 3.1.2 Concentration-Time Graphs 3.1.3 Kinetics and Mechanism 3.2 Experimental Rate Laws 3.2.1 Order of Reaction 3.2.2 The Rate Constant 3.2.3 Molecularity 3.2.4 Stoichiometry 3.2.5 Integrated Equations 3.3 Determination of Order of Reaction 3.3.1 Integral Method 3.3.2 Differential Method 3.3.3 Half-Life Method 3.4 Experimental Techniques 3.4.1 General Considerations 3.4.2 Techniques - In General 3.4.3 Techniques - In Detail 3.5 Kinetics and Temperature 3.5.1 The Arrhenius Equation 3.5.2 Determination of Activation Energy 3.5.3 Potential Energy Profiles 3.5.4 Effect of Temperature 3.5.5 Catalysis 3.6 Mechanism 3.6.1 Rate Determining Step 3.6.2 Elucidation of Mechanism 3.7 Theories of Reaction Rates 3.7.1 Collision Theory 3.7.2 Potential Energy Surfaces 3.7.3 Transition State Theory4 Liquid Metal Solutions 4.1 Solution and Composition 4.2 Surface and Interfacial Energy 4.3 Thermodynamics of Solutions 4.3.1 Partial and Integral Quantities 4.3.2 Ideal Solutions and Activity 4.3.3 Raoult's Law 4.3.4 Non-Ideal or Real Solutions 4.3.5 The Gibbs-Duhem Equation 4.3.6 Henry's Law and Dilute Solutions 4.3.7 Multicomponent Solution and Interaction Coefficients 4.3.8 Thermodynamics of Mixing Solutions 4.3.9 Excess Thermodynamic Quantities 4.3.10 Construction of Equilibrium Phase Diagram from Integral Free Energy-Composition Curves 4.3.11 Free Energy of Nucleation 4.4 Slags and Fluxes 4.4.1 Functions and Properties of a Slag 4.4.2 Structures of Slags 4.4.3 Slag-Metal Reactions 4.4.4 Fluxes Used for Non-Ferrous Metals 4.4.5 Structures of Flux Materials (Fused Salts) 4.5 Gases in Metals5 Aqueous Metal Solutions and Electrochemistry 5.1 Ionics I: Ions in Solution 5.5.1 Electrolytes 5.1.2 Aqueous Solutions of Electrolytes 5.1.3 Ionic Activity 5.1.4 Mean Ionic Activity 5.1.5 Debye-Huckel Theory 5.1.6 Measurement of Mean Ionic Activity 5.1.7 Acids and Bases 5.1.8 The Ph Scale 5.1.9 Buffer Solutions 5.1.10 Ph Measurement 5.2 Ionics II: Electrolytic Conduction 5.2.1 Measurement of Conductivity 5.2.2 Molar Conductivity 5.2.3 Variation of Molar Conductivity with Concentration 5.2.4 Kohlrausch's Law of Independent Migration 5.2.5 Transport Numbers 5.2.6 Conduction in Fused Salts 5.3 Electrodics I 5.3.1 Electrode Potentials 5.3.2 The Metal Electrode 5.3.3 Comparison of Electrode Potentials - Electrochemical Series 5.3.4 Diagrammatic Representation of Cells 5.3.5 The Standard Electrode Potential 5.3.6 Reference Electrodes 5.3.7 Indicator Electrodes 5.3.8 Cell Mechanism 5.3.9 Concentration Cell 5.3.10 Redox Potentials 5.3.11 Cell Thermodynamics 5.3.12 The Nernst Equation 5.3.13 Calculation of Emf (Cell Potential) 5.3.14 Concentration Cell Potentials 5.3.15 Application of the Redox Series 5.3.16 Kinetic Considerations 5.3.17 Variation of Redox Potential with pH 5.4 Electrolysis 5.4.1 Basic Considerations 5.4.2 Faraday's Laws of Electrolysis 5.4.3 Current Efficiency 5.4.4 Energy Efficiency 5.4.5 Current Density 5.4.6 Theoretical Cell Voltage 5.4.7 Polarization and Overpotential 5.4.8 Decomposition Voltage 5.4.9 Discharge Potential 5.4.10 Electroplating 5.5 Partition (Distribution) נof Solutes between Immiscible Phases 5.5.1 Extraction 5.6 Ion Exchange 5.7 Adsorption 5.7.1 Gibbs Adsorption Isotherm 5.7.2 Adsorption of Gases6 Metal Extraction Processes 6.1 Ore Preparation 6.1.1 Comminution Processes 6.1.2 Classification Processes 6.1.3 Separation Processes 6.1.4 Agglomeration Processes 6.2 Pyrometallurgical Extraction Processes 6.2.1 Drying and Calcination 6.2.2 Roasting of Metal Concentrates 6.2.3 Smelting 6.2.4 Matte Converting 6.2.5 Reduction of Metal Oxides 6.2.6 Fire Refining 6.2.7 Distillation 6.2.8 Halide Metallurgy 6.2.9 Continuous Extraction Processes 6.2.10 Pyrometallurgical Extraction Procedures for Selected Metals 6.3 Hydrometallurgical Extraction Processes 6.3.1 Leaching 6.3.2 Precipitation Techniques 6.3.3 Isolation Techniques 6.4 Electrometallurgical Extraction Processes 6.4.1 Electrowinning and Electrorefining of Metals from Aqueous Solutions 6.4.2 Electrowinning and Electrorefining of Aluminum and Magnesium and the More Reactive Metals from Fused Salt Electrolytes7 Metal Melting and Recycling 7.1 Metal Melting 7.1.1 Physical and Chemical Considerations 7.1.2 Removal of Gases from Liquid Metals 7.1.3 Melting Units 7.1.4 Cast Iron Production 7.1.5 Steelmelting and Refining 7.1.6 Melting Non-Ferrous Metals 7.2 Metal Recycling 7.2.1 Scrap Processing 7.2.2 Extraction of Secondary Metals8 Corrosion of Metals 8.1 Aqueous Corrosion 8.1.1 The Basic Corrosion Cell 8.1.2 Classification of Electrochemical Corrosion Cells 8.1.3 Types of Corrosion Damage 8.1.4 Pourbaix Diagrams 8.1.5 Electrode Kinetics 8.1.6 Determination of E-Log I Curves 8.1.7 Anodizing 8.1.8 Electropolishing and Electrochemical Machining 8.1.9 Environmental Aspects of Aqueous Corrosion 8.1.10 Prevention of Aqueous Corrosion 8.2 Oxidation - Dry Corrosion 8.2.1 Formation of the Oxide Layer 8.2.2 The Rate Laws for Oxide Growth 8.2.3 The Structure of Oxides 8.2.4 The Wagner Theory of Parabolic Growth 8.2.5 Growth of Thin Oxide Films 8.2.6 Scales on Multivalent Metals 8.2.7 Oxidation of Alloys 8.2.8 Oxidizing Atmospheres 8.2.9 Oxidation ProtectionAppendix 1. Electron Configuration of the ElementsAppendix 2. The Electrochemical (Redox) SeriesAppendix 3. Electrode Polarity and Ion Discharge in Electrochemicals and Electrolytic CellsAppendix 4. Galvanic SeriesAppendix 5. Solutions to Calculations in Chapter 2Index