Metal Extrctn.

Notes

METAL EXTRACTION

The commercial extraction of iron from its ore is

A BLAST FURNACE

Ores: Haematite Fe2O3 Iron (III) oxide

Magnetite Fe3O4 (converted to haematite) FeO + FeO

Siderite FeCO3 (converted to haematite).

Extraction of Iron its Ore Haematite

1. A dried mixture of heated iron ore(usually haematite), limestone and coke called
the charge is carried to the top of the blast furnace by skips on a conveyer belt
where it is dumped into the hopper.

2. Hot air is blown into the furnace through holes called tuyeres (pronounced to-
years) near the bottom. The charge glows as the coke in it burns in the preheated
air, producing carbon dioxide and generating a tremendous amount of heat which
 Metal Extrctn. Notes

maintains the temperature at 1900 ºC. Simultaneously the limestone at these

temperatures begins to decompose to form Calcium oxide and carbon dioxide.

C(s) + O2(g) → CO2(g) + heat –ve ΔH (highly exothermic).

CaCO3(s) → CaO(s) + CO2(g)

3. The carbon dioxide produce from these two reactions reacts with more hot coke
higher up the furnace to form carbon monoxide by reduction. This process is
endothermic, and the heat absorb reduces the temperature to about 1100 ºC.

CO2(s) + C(s) → 2CO(g) +ve ΔH (highly endothermic)

4. The carbon monoxide gas rises up the furnace and being a powerful reducing
agent reduces the iron (III) oxide ore – haematite to iron. This takes place at a
temperature of 700 ºC.

Fe2O3(s) + 3CO(g) → 2Fe(s) + CO2(g)

Fe2O3(s) + 3CO(g) → 2Fe(s) + CO2(g)

NB – As the iron gradually moves down the furnace it melts (Fe – m. p. 1535 ºC) and
the molten iron trickles to the bottom of the furnace whilst absorbing carbon which
lowers its m. p. as well.

5. The iron ore contains significant amount of impurities in the form of sand –
silicon (VI) oxide SiO2 that must be removed. This is achieved by the reaction
between the Calcium Oxide CaO formed from the decomposition of limestone in
the earlier stages. The acidic oxide silica SiO2 reacts with the basic white lime
CaO to form molten calcium silicate or slag. The molten slag runs to the bottom
of the furnace as well but because it is less dense than the molten iron it floats on
top of it.

CaO(s) + SiO2(s) → 2CaSiO3(l)

NB – The molten slag also acts as sort of a shield in that it prevents any oxidation of
molten iron by the hot air blast at the bottom of the furnace.

6. The molten slag and the molten iron are tapped off (run off) at separate holes/taps
from time to time. The process is continuous.

7. The molten iron is run into sand moulds to cool and solidify into lumps called
‘pigs’, this also referred to as cast iron.

8. Wrought iron is the purest form of commercial iron. It is 99% iron and contains
less than 0.25% of carbon.
 Metal Extrctn. Notes

EXTRACTION OF ALUMINIUM

The Commercial extraction of aluminium is made possible by two scientist the American
Martin Hall and the French chemist Paul Heroult who both independently discovered the
same process in 1886. Hence the process is jointly named in their honour – the Hall-
Heroult process.

Graphite Anodes

+
-

steel case

graphite cathode

electrolyte
purified Al2O3 dissolved
in molten Na3AlF6

molten Al molten Al tapped off

Hall /Heroult cell used for the extraction of Aluminium

Extraction of Aluminium from its ore Bauxite

Ores used : Bauxite – impure Al2O3.2H2O

Cryolite - (Sodium Aluminium Hexfluoride).

The process develop to extract aluminium from aluminium oxide (alumina) is called the
Hall-Heroult process.

The extraction is carried out by electrolysis in the following three stages:

Stage 1.

a. The bauxite an impure form of aluminium oxide is first treated with sodium
hydroxide NaOH to obtain pure aluminium oxide – removing impurities
such as Iron(III) oxide and sand SiO4 .

b. The purified aluminium oxide bauxite is then dissolved in molten cryolite (Na3AlF6).
 Metal Extrctn. Notes

 NB: Cryolite is used to reduce the working temperature of the Hall-Heroult

cell from 2017oC to between 800oC and 1000oC.

 NB: Cryolite is used to increase the conductivity of the melt(i.e. ionic mixture
of alumina)
Stage 2.

a. The aluminium oxide/cryolite solution is electrolysed using graphite

electrodes which are lowered into the molten mixture from above.

Stage 3.
.
a. The negatively charged oxide ions are attracted to the anode (+ve electrode),
where they lose electrons to form molecules of Oxygen gas.

Oxide ions → oxygen molecules + electrons

At Anode: 2O2-(g) → O2(g) + 4e-

 NB: - At the working temperature of the cell the oxygen liberated reacts with
the graphite anodes producing carbon dioxide gas CO2.(As a result the
anodes burn away and have to be replaced on a regular basis.)

b. positive aluminium ions are attracted to the cathode (-ve electrode), where
gain electrons to form aluminium metal. The molten aluminium collects at
the bottom of the cell and is siphoned off via tap at regular intervals.

Aluminium ions + electrons → Aluminium metal

At Cathode: Al3+ (l) + 3e- → Al(l)

 NB: - The cathode is also made from graphite which lines the steel vessel
containing the the electrolytic cell.

The overall reaction which takes place in the cell is denoted below:
electrolysis

Aluminium oxide Aluminium + Oxygen

electrolysis

2Al2O3(l) 4Al(l) + 3O2(g)