21-Mat-A3 Structure and Characterization of Materials, Dec-10-Met-A3 2018: worked solutions

Paper format. National Exams, December 2018 — 10-Met-A3, Metal Extraction Processes. Three hours, closed book, one approved calculator (Casio or Sharp). Seven problems of 20 marks each; the rubric asks for any five, and only the first five in the answer book are marked. All seven are solved here, because this set is a study resource rather than an exam script.

Note on the exam title. The printed exam header reads 10-Met-A3, Metal Extraction Processes. The content is extractive metallurgy — mineral processing, mass and heat balances, pyrometallurgical roasting, copper and aluminum production, and electrometallurgy — and is answered as such.

Reference texts. The answers below are keyed to the works normally recommended for this syllabus code:

F. Habashi, Textbook of Pyrometallurgy — roasting, smelting, mass and heat balances.
T. Rosenqvist, Principles of Extractive Metallurgy, 2nd ed. — ironmaking, non-ferrous smelting, electrometallurgy.
B. A. Wills and J. Finch, Wills' Mineral Processing Technology, 8th ed. — pulp density, comminution, froth flotation.
D. R. Gaskell, Introduction to the Thermodynamics of Materials — heat capacities, reaction enthalpies, electrochemistry.
W. G. Davenport et al., Extractive Metallurgy of Copper, 5th ed. — smelting/converting/refining and SX-EW flowsheets.
ASM Handbook, Vol. 2 (Properties and Selection: Nonferrous Alloys); CIM (Canadian Institute of Mining) practice literature for Canadian smelter/refinery practice (e.g. the historic Cominco smelter at Trail, BC, and Rio Tinto's Kitimat, BC aluminum smelter).

21-Mat-A3 Structure and Characterization of Materials: Dec-10-Met-A3 2018