Smelting is a process of applying heat and a chemical reducing agent to an ore to extract a desired base metal product. It is a form of extractive metallurgy that is used to obtain many metals such as iron, copper, silver, tin, lead and zinc. Smelting uses heat and a chemical reducing agent to decompose the ore, driving off other elements as gases or slag and leaving the metal behind. The reducing agent is commonly a fossil fuel source of carbon, such as carbon monoxide from incomplete combustion of coke—or, in earlier times, of charcoal. The oxygen in the ore binds to carbon at high temperatures as the chemical potential energy of the bonds in carbon dioxide is lower than that of the bonds in the ore.
Electric phosphate smelting furnace in a TVA chemical plant (1942)
Copper smelter, Chelyabinsk Oblast, Russia
Electrolytic cells at an aluminum smelter in Saint-Jean-de-Maurienne, France
Cowles Syndicate of Ohio in Stoke-upon-Trent England, late 1880s. British Aluminium used the process of Paul Héroult about this time.
Ore is natural rock or sediment that contains one or more valuable minerals concentrated above background levels, typically containing metals, that can be mined, treated and sold at a profit. The grade of ore refers to the concentration of the desired material it contains. The value of the metals or minerals a rock contains must be weighed against the cost of extraction to determine whether it is of sufficiently high grade to be worth mining and is therefore considered an ore. A complex ore is one containing more than one valuable mineral.
Manganese ore – psilomelane (size: 6.7 × 5.8 × 5.1 cm)
Lead ore – galena and anglesite (size: 4.8 × 4.0 × 3.0 cm)
Granitic pegmatite composed of plagioclase and K-feldspar, large hornblende crystal present. Scale bar is 5.0 cm
Piece of kimberlite. 11.1 cm x 4.5 cm