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Smelting separates usable metals from mixed deposits. The process involves heating the material with an agent to force precipitation of the desired mineral. Density changes allow for removal of desirable ore. Industrial metal production weighs the value of ore against the cost of mining.
Smelting is a process of extracting usable ore from mixed deposits where people find ore bonded to other metals, rock, and foreign material. It is very unusual to find deposits of pure ore and this method allows people to separate the useful metals. The invention of this process was an important step in the development of human societies, enabling people to make more complex metal products and alloys.
In the smelting process, people heat the material with an agent to start a chemical reaction. While people often refer to casting as another form of casting, simply casting the material isn’t enough. The chemical reaction is needed to force precipitation of the desired mineral, and it can be helpful to add a flux to bind to the particulate materials, forming slag, a mass of unwanted material that will settle to the bottom of the furnace where people make their smelting.
As the ore precipitates and collects, density changes in the composition of the material will cause it to form layers, allowing the operator to remove the desirable ore. After smelting is complete, people can extract the byproducts and discard them, although there are sometimes uses for them, such as combining them into aggregate concrete mixes. The yield of any given smelting cycle varies depending on the quality of the feedstock and the type of ore people are attempting to mine.
People need to carefully monitor the conditions during melting. The heat must be adequate for the ore and the furnace requires good air circulation to fully heat all material, avoiding situations where it forms bulk and does not have a chance to react chemically while in the furnace. People also need a non-reactive furnace lining and need to be careful with certain substances because they can produce toxic fumes and can make people ill.
Industrial metal production relies on a number of processes to extract usable ore from deposits. It can be a painstaking procedure. Companies weigh the value of the ore they are mining against the costs of mining to determine if smelting is an efficient and appropriate processing method. In some cases, the ore may be left alone because it would cost too much money to extract, even if it is valuable. People in the area around a metal mine may notice waste material with traces of the metal that would be too expensive to recover inside.
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