How are raw metal ores processed before they are made into manufactured parts?

Raw metal ores undergo a multi-stage process to transform from raw mineral deposits into refined metals suitable for manufacturing.

Mineral Processing

Initially, ore is mined alongside unwanted rock and minerals known as gangue. Through mineral processing—also called ore dressing—the valuable minerals are separated from the gangue using physical properties, such as magnetic, gravity, or flotation separation.12

Extractive Metallurgy

Once concentrated, the ore undergoes extraction to separate the metal from its chemical compounds. This is achieved through two primary methods:
* Pyrometallurgy: High-temperature processes like roasting (converting compounds to oxides) and smelting (melting the ore to separate metal from waste).3
* Hydrometallurgy: Chemical processes such as leaching, where metals are dissolved from the ore using an aqueous solvent, or electrowinning to deposit metal ions onto an electrode.31

Refining

Finally, the extracted metal is refined to achieve the desired purity level. This may involve further pyrometallurgical, electrolytic, or chemical treatments to remove remaining impurities before the metal is cast into forms like ingots for manufacturing.34