Foundation Course for +2 Students

EXTRACTION OF METALS
Sym bol
Cu
Atom ic Num ber
29
Atom ic mas s
63.57
Elec troni c Conf igura tion
KL MN
2 8 18 1
2
1. 1s 2s 2 2p 6 3s 23p 63d 10 4s 1
OCCURRENCE
C?PP~r occu rs in its_ native state in many countries
like Canada, New Mexico, Sweden
Sibe ria and ~hodes1a (presently Zimbabwe) . In the
man y countries. combined state, it occurs widely;~
The principal ores are:
(a) Sulphides :-
• Copp er pyrites or chalcopyrite
[Cu2S . Fe2S3 or 2 Cu FeS ]
2
• Copp er glance or chalcocite [Cu S]
(b) Carbonates : 2
• Malachite : [Cu(OH)2.Cu C0 ] Green
3
• Azurite [2 CuC03. Cu(OH)2]. Blue
(c) Oxide :-
• Cuprite or Ruby Ore [Cu 20] Red
INDI AN SOURCES :
The sulphide ore of copper, copper pyrites is found in
2. Orissa, Bihar, Sikkim and Rajasthan.
EXT RAC TION OF COPPER
Copp er is generally extracted from the sulphide
ore, i.e., copper pyrites (CuFeS ).
Altho ugh the percentage of Cu in this ore is very smal 2
l (hardly 2%) but almost 75% of
the metal is produced the world over using this ore.
The ore contains much iron (as sulphide) and silice
ous impurities. The separation of •
copp er from these materials is brought about by the
metal (i.e., iron) to iron oxide and the ease of its comb
preferential oxidation of the base
ination with silica to form ferrous f
•
silicate, which is removed as slag.
The various steps involved in the extraction of copper from ~s ore,
copper pyrites, are as follows:
3. CON CEN TRA TION OF ORE r::::= == -Com press ed
Before extraction of copper from the ore, it is Air
nece ssary to remove the earthly materials and l~~~~~~Foam + sulphide
-_-_-_-_-___ _-_-_-_-________ Ore
impurities . Copp er pyrites is a sulphide ore, as
such it is concentrated (dressed or enriched) ~~:-.:-.--:~:-.. -:-.--.:-:-.:-:~:::: i-- Impuri ties
by the froth floatation process. The ~ulphi~e -~ - -- -,
ore is powdered and the powdered ore 1s put in
FROTH FLOATATI ON
a tank contain ing some pine oil. The water in PROC ESS
the tank is agitated by blowing in compressed
air due to which froth is formed .
The ore particles rise to the surface i~ the form
~f a froth because they get
preferentially wetted by oil. Gangue part~cles _do not
stick to t~e froth _and get settled
at the bottom and are discarded. The froth 1s skimmed
off from time to time .
on keeping, foam settles down and concentrated
ore is obtained.
4. ROASTING
:..... ,,
•r.
·: ::f , ., ..
,.
f .:"
· i~, ~~--~Lt• ~ ..!
\~ ·.~:~
 - --- - -
F METALS
Foundation C ents EXTRACTION O
OUrse fo r +2 Stud

the presence o
f excess of
th ng ly he at ed in oru s,
In this Process ' e concentrated ore is stro im pu rit ie s of sulfur, phosph
air on the h furnace . Th e
ony an d ea rth _of reverberato,:y e form of the ir volatile oxides .
antim oved 1n th
arsenic are rem
S + 02- -- )S 2 0
0
4P + 3 02- - ) 2P 2 3
2Sb 20 3
4Sb + 302 ~
ide ,
4A s + 3 0 2 -- ) 2A
s203
s su lp hi de an d cuprous sulph
Th d into ferrou
e r py rit e (C uF eS2) is converte
wh~ ~ p p
IC are further
, partially oxidized
0
Cu S + 2 FeS + S 2
2CuFeS 2+ 0 2 ~ 2
Copper pyrite
2Cu20 + 2S0 2
2Cu2S + 302 ~
2Fe0 + 2S02
2FeS + 302 ~ a little
5. ELT IN G ed bl as t fu rn ac e , together with
SM a water jacket is provided
e or e is now charged into d th en m el ted . The furnace
Th
a (sand or quartz
), an ed . The
(i)
an d so m e si lic h w hi ch a bl as t of air is admitt is
coke roug at very little coke
ba se w ith a ro w of tuyeres th th e he at so th
at the ides most of component
e ore itself prov the iron sulphide
combustion o f th im inat e m os t of mbining
ed . Th e sm el ting serves to el rrou s ox id e , th e latter then co
need d into fe
hich is converte
of the pyrites , w licate
silic a to fo rm fusible ferrous si
w ith
3 Fe0 + 2S02
2FeS + 302 ~ slag)
FeSi03 (Fusible
Fe0 + Si02 ~ (th is is
2Cu20 + 2S02 form back Cui$
2Cu2S + 302 ~ us su lp hi de to
bines with ferro parison to that of
copper).
C up ro us ox id e so formed com ox yg en in co m
(ii)
r affinity of iron to
wards
because of greate F e0 . (W as te qases
~ C u2 S +
Cu20 + FeS s with
s ox id e th us formed combine
Ferrou form slag. ~ire bricks Ii.Ding
silica to
slag)
Fe Si0 3 (ftisible
Fe0 + Si02~ to top
thus formed rises
The iron silicate hole,
m ov ed as a slag through slag
and re ed with
s sulphide, mix
while the cuprou Copper
ou s su lp hi de , now called as
ferr (It is to
e lower layer.
Matte, forms th cuprous
oxidation of
prevent the the removal of
iron
hi de its el f th at slag
sulp
t ca rried out to Matte
no
sulphide is st ep ) : Blast Furnac e for Co P,pe
e
r Extraction o f the
bottom
io n in th is Fi 9. id ed at m
complet M " . fro m th e tap nole prov
"C moved
Th e opper atte 1s re
furnace . ar
M E R IS A TI O N is in tro du ce d into a small e
6. BESS E blast furnace · p
m ol te n co pp er matte _from the er co nv er te r fo r steel but h g tu ye r~s
The m avm
(i)
co nv er te r re se mb/rng the Besse) which are ,.
h . This
shaped
~ (in st ea d of at the base d t d pl~c ed.be__. h,~h.;..enoug which
in . the, . si de
ables the metal Produce 0 rop f .,: low ~~ e re s '
.=:,- .
a~~_gement ;e··,:, • ' · -~- · . . '
- .
' ~. . . ~ ".' .
..
 Fou nd ation Course for +2
Stud ents
•
(i
EX TR AC TI ON OF ME
TA LS t
Pr?vents the oxidizing
action of the blast. Th
e iron sulphide, that es
4
oxidation during smelting capes
gets oxidised to iron oxide
At _this stage the cuprous , which forms a slag with
sulphide gets partially silica .
which then reacts with the oxidised to cuprous oxide
remaining of the sulphide ,
2Cu2 S + 30 2~ 2Cu20 to form metallic copper.
+ 2S 0 2
Cu 2S + 2Cu20 -➔ 6Cu
+ S0 2
Th e reaction between the
oxide and sulphide is ve
the heat set free Is suffic ry vigorous and noisy, an
(ii) ient to keep the charge In d
When the reaction is ov the fused state.
er, the molten copper is
product when s~lid, is run off into sand moulds.
known as blister copper, The
a~p~arance t~at 1t a~sume because of the blistered
s during solidification, ow
dioxide held tn sol_ut1~n ing to the escape of su
by the molten copper. Bli lfur
copper, the rest be1n_g. iro ster copper contains about
n tog 98 %
As, Sn, Pb, Zn etc ongInally ether with small amounts of silver and gold and
present in the ore. also

Frame

i
Tuyeres Tuyeres

Molten
copper
Fig : Be sse me r converter for
Extraction of Copper
7. REFINING OR PURIFICAT
ION OF COPPER
Th e fol low ing two steps
are involved in refining of
(i) POLING: Th e blister copp Blister copper.
er is melted on the heart
and the molten mass is h of a reverberatory furna
stirred with green poles of ce
pr oc es s facilitates the co wood in presence of air.
nversion of As, Sb, Zn an Th e
an d the oxidation of Fe, d S into their volatile ox
Ni, Sn, Pb to their respecti ides
as sc um from the surface ve oxides which are remov
of molten copper metal. Cu ed
is reduced ba ck to copp prous oxide formed, if an
er metal by the hydroca y,
the de co mp os itio n of gre rbons like methane forme
en poles of wood d by
3Cu 20 + CH4 ~ 6Cu
+ CO + 2H20
Co pp er th us ob tai ne d aft
er poling has purity of'
°' 99 .5%
(ii) ELECTROLYTIC REFIN
IN G .
Co pp er obtained by ele
ctrolytic refining has a pu
kn ow n as ELECTROLYT rity of 99.95 to 99.99%, and
IC COPPER. is
Th is mo st modern metho .
d involves th~ electroly~1
or the co pp er obtained aft s of crude co pp er Le, bli
er poling. ste r
copp~rt lates, each 3 ft square an Fo r thi s purpose, the crude metal

1
st
i
~a in iea d-l ine d tanks
~ hugH SO -tand
d 3/4 inch thick. These are
containing cop~er _
hung at int erv als
sulphate _solution, ~.9itji
is

fi~d .·w ith

·di lut e 2 for m the an od es . Th e ca
4, ,q r • tl)odes c~nsIst of thi n 'p1ate
,: 1 , , , I 'I, . .. , ,
s~o f pure
~
•
J:
..:.,..,. •
.. ""' .. •'t '..
Fou nda t·
---
tone
ours e for +2 Students
-~---· EXT RA CTI ON OF ME TAL S

cop per which

be ea •
: . are coated Wlth graphite to perm it the metal deposited on
1
SI Y stnpped off. them to
As
mo the elec
. t ro 1ysis
· proceed
s , the copper from the anodes together
Whi~ active metals, e.g., Zn ,Fe, Ni etc. with trace~ 0 f
th e less active metals, present as impurities . go into solution ,
th gold and silver, are left und issolved and
e bottom of the electrolytic tank as ANO settle at
DE MUD . At the cathodes copper
alone ge~s deposited , because the volta
ge employed ( 1 .3 volts ) ls not sufficient
to deposit the more active metals pres
ent in solution .
The cop per thus obtained is almost
cent-per-cent pure
t= == ~~ ==::i;:==::::::::::ii;::::::::::::::::::::
::=::::::1f'ffl1~
• Anod e
t=== ==~~~:::::::::}:=::;;=:=:::=::::;::==::::::::::
::=:lfffl7R-- Cathode

Cathode (Pure Cu)

_ll..:.l,~-
Anode (Impure Cu)

cuso ~ Solution
I • •
: : •: :: : : • a: : ~ i i 1i : ! · • .. ·

Anode sludge
('Anode Mud' )
Fig : Electro-refining of copper.

SO LVE D PRO BLE MS

Com ple te the following by identifying

1 [A1,[B1,[C1 and [D1
CuS 04.S H20 1000c >[A] 2sooc >[B1 soooc >[Cl + [D1
CuS O .5H O 1000 c ➔ Cu SO 4. H2O 2sooc ➔ Cu SO 4
4 2 --_,
[A] [Bl
2cu SO 4 soooc ➔ 2 CuO+ 2SO 2+O 2
[B] [C] [D]

Wh y is copper sulphate p~ntahydrate

2 ~oloured? . . .
In the presence of H2O as hga_nds, .d-or
b1tals of Cu (II) ,on split into two sets,
lower energy an~ the 9ther, 'l{tt~ h~gher_ one with
en~rgy. t rQr:n. tt)e wt)ite \ight falling _~:m
1
·, .~- wavelength i~ , b~orb:rJ, f,9,r ;e~c1tat\ tt, Jed
~>n of
-~1~ -( the process, thu§; the:~rp-~l~mentary colour low ~17-ft~o·'¼~~
er to high e~,.
e ner gy \eve\. \n
,' I
v,z t51ue 1s reflected . ~ ·- ·~~
 EX TR AC TI O N OF MET
ALS
3 W hy i~ C~ al co ci te roa~
te d and not _calcined
Ro as tm g in vo lve s he in the recovery of copp
atin g of an ore m the pres er?
in vo lv es he at in g of the ence of excess of air wh
ore ei th er in the absenc ile calcination
Ro as tin g of chalcocite e of in presence of limited
is necessary because supply of air .
As , Sb et c pr es en t in it not only removes the im
it as their volatile oxide purities of s, P,
Ca lc in at io n on the ot s but also partially oxidise
he r hand will neither be s Cu S
to co nv er t Cu S to Cu able to oxidise the impuriti 2 to Cu 20 .
2 2 0 . Therefore, chalcocite es nor be able
is roasted and not calcine
d.
4 In m oi st ai r co pp er co
rr od es to produce a gr
In pr es en ce of moist een layer on the surface
air, a thin film of green . Ex pl ai n: its
su rfa ce and hence co basic copper carbonate
pper corrodes: is formed on
2C u + 0 2 + H O + C O
2 2 ~ CuC03, Cu (OH)2
Basic copper carbonate
5 W ha t is be ss em er iz at (green)
Th e pr oc es s in which io n? .
copper oxide reacts wi.th hide to form co pp er m et
al is
ca lle d bessemerization copper sulp
.
6 Na m e at le as t five im
po rta nt ores of copper
(i) Co pp er pyrites , Cu .
FeS2
(ii) Co pp er glance, Cu
2S
(iii) Cuprite, Cu 20
(iv) Malachite, Cu(OH)
2.CuC0 3
(v ) Azurite, Cu(OH)2.2C
uC03

AL TH AT SA TI AT ES
IR O N : TH E M ET TH E AP PE TI TE O F M
A C H IN E- AGE

Sy m bo l Fe
At om ic nu m be r 26
At om ic m as s 55.84
. 2, 8, 14 ,2
El ec tro ni c configuratio
n
K, L, M, N
6

O CC UR RE NC E
. ·t iron does not oc cu r free
Except 1n ~n :ie sam.ples of meteon es, in nature. In th e co m bi
ne d st at e it
is widely d1stnbuted ,n n~ an d co ns titu te s about 4.5 % of ea rth s
In th e co m bi ne d state, ture_ f nd in th e fro m cr us t. .
,ron ,s ou of its ox id e, ca rb on at .
e an d su lp hi de . Th e
or es of iron are: m am
(i) Ha em at ite Fe203
(ii) .... Lim ~£~\~ Fe2 03. 3H 20 .
1
,' : $' 't~ ~~~ (H yd ~~te~ J~:m c: 9~id e)
,-
(iii ) ~ Mag ~·etite Fe3d 4(or~~e 9:. Fe203)
 Foundaf
ion Course for +2 Students
EXTRACTION OF METALS

Siderite
FeC0 3
(Spath le Iron ore)
Apart from abo . . . . .
howev ve ores, iron occurs In the form of its sulphide 1n iron pyrites, FeS 2. Iron pyntes 1s,
other ~: n~t used to extract Iron commercially because of Its very high sulphur content and
0
lndi . jec~ionable impurities. It Is normally used for manufacture of H2S04_
a IS having a very large reserve (about ¼ of the total world reserve) of both blast furnace

- i~~de (fo~ making cast iron) and high grade iron ore (for making steel). It is found mainly in
1
ar, Onssa, Madhya Paradesh / Chhattisgarh, Karnatka and Goa . India is exporting iron
ore to Iran and Japan. Indian iron ore contains about 60-64% iron.
~ The main steel plants (Integrated steel plants) are located at Bhilai (Chhattisgarh), Durgapur
and Bumpur (West Bengal), Bokaro and Jamshedpur (Jharkhand), Rourkela (Orissa),
~ Bhadravati (VISL, Kamataka), Vishakhapatnam (RINL, Andhra Pradesh). Besides these

--..
~
there are two Alloy Steel Plants, one at Durgapur (W. B) and the other at Salem (Tamil Nadu)

EXTRACTION OF IRON

..• In India, iron is generally obtained from haematite. The metallurgy comprises in the
calcination or roasting of the ore, followed by smelting; but in certain cases, especially for the
low-grade ores and magnetite, preliminary washing and magnetic separation are resorted to
for the concentration of the ores. These two operations are not generally used in Indian
production, which used high-grade haematite .

..•• CONCENTRATION OF THE ORE

• The first step involved in the production of iron metal from its ore, haematite is

• Washing : The large lumps of ore from mines are crushed to 2" to 3" size. These are
washed with jets of water directed against the stack of the ore to remove the

• clays and other adhering impurities .

• ROASTING AND CALCINATION OF ORE

•I The ore (oxides or carbonates) is mixed with a little coal and strongly heated in kilns with a
sufficient supply of air. Sulphur and arsenic escape as S02 and As20 3, along with moisture,
and the carbonate is decomposed to the oxide with the liberation of CO 2; ferrous oxide is also
oxidised to ferric oxide, so that formation of ferrous silicate is avoided in future operation. The

• ore is simultaneously rendered porous, which facilitates subsequent reduction by

•
reducing gases .

SMELTING OR REDUCTION OF THE ROASTED ORE

• The roasted ore is mixed with about one- fourth of the weight of lime stone ( used as a
flux) and about half of its w~ight of metallurgical coke (used as a fuel as well as the
• reducing agent) and ~harged into the bl~st furnace where ferric oxide is reduced to iron. The
► ore and _the flux are mixed together outside the furnace and the mixture is added in alternate
layers with coke .

~·· •.tJ-•. ,....

\ f!''1: :.
' I
 Foundation M ET A LS
Course for +2 Stud EX TR AC TI O N O F
ents
.
1
sing is of '!1' d s;~:
The bl ast furnace '
is a ete rs high. Th e outer ca
shaft about 25 -30 m
er tall _ fractory fire -clay bn ck
s. f
Plates riveted togeth ed wi th hig hly re
while the interior is lin ound . The t~pb~
furnace is kept in th ' al position by means of iron pillars fixed to the grised wi th swta . e
e vertic ter po
the furnace is a do ub le cu p and cone device ( coun th dunng
Weights) wh · h prov
ided W ith
fu rn ac e ai r-tig ht in such a way at
outh of the th e furnace .
chargin IC makes the m ce ss to th e hot charges within
e ge ts ac e. gaseous
air from outsid cape of hot gases (i.
There · g, no colder fur na ce for the es
near the top of the
Pfi d IS an outlet (flue)n).
0 ucts of combinatio
rd about two-thirds
top towa
ases gradually from the est part where th e matte~
The internal d'iameter of the furnace incre down to the low
gth an d then na rrows down fairly quickly from 3-6 met~rs. The
n~ rr o~ !~
?f its len fu rn ac e va rie s st part is ca d
The diameter of the lows down to the wide
iron and slag collect. an d the pa rt tha t fol
ea is ca~~e
d the throat the next narrowing a:
part at the top is calle m the wi de st pa rt to
called
ce. The portion fro slag at the bottom is
The Body of the furna lte n me tal an d the
receptacle for the mo d closed by ~lay
the Bausch while the g ho les on e above the other, an
provided wi th tw o plu ~ole) . A ltttle
hearth. The hearth is er ho t~) an d slag (through ~pper r
lten iron (throug h tow
openings fitted wi th a nu m be
for removal of the mo d wi th a nu m be r of 'tw ') fo r
the hearth is provide yeres (also spelled
as yers ,
above these two holes , n no zz les , ca lle d tu
. ter-cooled iro
opening fitted with wa t B00°C).
wing pre-he ated co mpressed air (at abou
blo

at the
BLAST FURNACE OP
ERATION
rted by bu rn ing so me quantity of wood
blast furnace is first sta y and clean ai r
The operation of the flu e of the furna ce, are mixed with dr
caping through the 0°C by
hearth. Hot gases, es ier and sc ru bb er ) and heated to about B0
passing through a dr through a pair of sto
ves (C ow pe r
(obtained by previously d co oli ng by pa ss ing po we rfu l
of heating an tuyeres by means of
a regeneration system fur na ce thr ou gh the
then blown into the
stoves). The hot air is
blowers.
T FURNACE
AC TIO NS TA KI NG PLACE IN THE BLAS fur nace , during the smelting
of iron. The
RE ide the blast
anges take place ins of the furnace, viz:
A series of chemical ch three differ en t se ctions along the length
place in
changes generally take (4 00 - 900°G)
pe r zo ne - The zone of reduction
(a) Th e up -1100°C), and
le zo ne - Th e zo ne of slag formation (900
(b) The midd 10 0- 1500°G)
e low er m ost zo ne - The zone of fusion (1
(c) Th
t air blast through
• The oxygen of the ho
carbon of coke to
the tuyeres bums the
the hearth of the
carbon monoxide near
furnace:
2C + 02 ~ 2CO
at the mouth of
• With excess of oxygen
t bums of CO
the tuyeres, carbon firs
CO on passin;
wfJ!_ch i~- re1u9ed to 2:. h·ot
ite• , ....,
{ ~~
ugp. +,;,. ,_ L:'Pper l~y er of· wh
J~rgee •· 11 •
• ✓, 111 ':-.1.rr ~q".- 1· ·•
~o f\t . f~ -,, ' ·
· --·
'. ~ ': ' (. ·
\:'{' ~;i:z. ·:
'-' .w. .'! . . .
1

'-'
Found
ation c
~ for +2 Students EXTRACTION OF METALS

C + O2 ~ CO2
CO2 + C ~ 2co
While hot
Coke

The sequence 0 f
are as follow . reactions taking place In the three different zones of the blast f
(a) Re . s. urnace
actions in the upper zone (400 - 900°C)
~ th e top of the furnace (temp 400°C), the charge is pre-heated and driedThe d .
t arge descends along the furnace and passes through zones of grad~all . r~ed
4ooac Y nsing
empe~ature. At a little lower region where the temperature is above
monoxide of the ascending gases reacts with oxides of iron: ' carbon
3FeO + CO ~ 2Fe3O4 + CO2
Fe2O3 + CO ~ 2FeO + CO2
Fe3O4 + CO ~ 3FeO + CO2

Further down, where the temperature is above 650°C, FeO is reduced to metalr .
FeO +CO~ Fe+ CO 2 ic iron.
In this region, the CO 2 formed is also changed to CO by reduction with hot carbon d
a portion of CO decomposes in contact with hot spongy iron into CO 2and C: an
2CO ~ CO2+C

(b) Reactions in the Middle zone (900-1100°C)

At about 900°C, the glowing particles of carbon complete the reduction of oxides of
iron to the metallic state :
Fe2O3 + 3C ~ 2Fe + 3CO
FeO + C ~ Fe + CO
• At this stage, limestone, which was added to the charge decomposes to Cao and
CO2
CaCO 3 ~CaO+ CO 2
· Lime
The lime (CaO) thus formed combines with the impurities of the ore (mainly
siliceous matter) to form a slag of CaSi03
CaO+SiO 2 ~CaSiO 3
Slag
The spongy iron produced in this stage, absorbs some quantity .?f carbon a~
C,

sulfur from the fuel, as will as some p~osphorus, manganese an~. sihco;~
0
th~ ;1~
the reduction of calcium phosphate, oxides of manganese and silica P
ore.
(c) Reactions in the lower most zone (1100-1500°C) . b 0°c when
th t perature nses a ove 110 '
Further down in the Bosch of the furnace, e en:' !ready stated above)
the impure spongy iron (containing C, S~ P,
51 aocis :~w~st:the hearth, where th e
melts and the slag also fuses. The fused mixtu~e travehl h t air blast of the tuyeres by
·d· ·ng action oft e Q , -11

molten iron is prevented frc:>m t_h~ oxi

121
. • ~ •:• . :~ • • ~nttap ·
••

the layer of the lighter slag res~1ng ~b~ve. · ·. ~felf from the differe, ·' ··
~I ~ ~fe tapped of s~par ~
• . .)~ -holes.:''from time to time. .
. 1- ihe~.si'ag' and the molten met_ 7 11 ,.
,. ;1· l
 Fou nd ation Cou rs o for +2 Studonto
EX TR AC TIO N OF METALS

The molten molal ls cas t Into moulds

and ls known as Cast Iron or Pig Iron
molten metal may also be directly 0on . The
l l:o tho stool making furnaces (also kno
Steel Melling Shops, S.M.S.) for con vers wn as
ion of molten metal to steel.
The composition of cast Iron Is quite
variable
Typical samples of cast Iron may have
compositions as follows:
Carbon 2 to 5% (Graphite+ Non -graphltlc carbon)
Manganese 0.2 to 1%
Sulphur 0.3 to 1%
Phosphorus 0.5 to 1%
Silicon 1- 2 %
Iron Remainder

FLOW DIAGRAM FOR THE METALLUR

GY OF IRON
Qrn (Fe20 3 or FeC03)
(Run-of-mine)

Pulverization
PULVERIZED IRON ORE
Haematite (Fe 20 3) ,or Spathlc Iron ore,
FeC03
CONCENTRATION
(Washing and magnetic separation)
~---'-----,
Concentrated
ore

Roasting with coal and sufficient air in

reverberatory furnace
Roasted Mass
Smelting-cum-carbon reduction with coke
and
lime (flux) in blast furnace

Molten iron (impure) or cast iron Slag (mainly calcium silicate)

Transferred to Cast into moulds

steel making Pig-Iron
furnaces
A-Sl-fReN
Cast iron ls .a har~ ~· brittle, cry~talline .~ .
~~Ii?, .~ it~ rel~tively low _melting point.
Impure form of irol'.'I. and contains ma: It is the most
iy impurities. ,It can neither be l1hamm
ered .. (non ~
!""!'19 Fo
undation c
....._ ourse for +2 St d

~ --- ~ :--- -u_ e_nt_s___________e_x_T_R-=A~C=-T~ IO=-N~ :_

O~F~ M~E~T~A=L:S
l9rnalleab1 ) ,r .
i e nor ,t can be d . . .
• s ~ good casting met rawn ,~to w1~es (non-ductile) . Because of Its high sil\con content, it
radiators for auto b/ I and articles like drainpipes, gutter pipes , manhole covers ra\\\ngs
• Cast iron ex· t . mo I es etc are easily cast from it. ' ·
{i) Wh·,t IS s tn tw? forms; depending upon its carbon content.
e cast - iron
• It contain
a s !1"'ost of the carbon present as impurity, as Iron carbide (Fe 3C), also known
s cementate, and
• (ii) Grey cast iron

•
I
In gray cast iron , the carbon remains dispersed through out the mass as the flakes /
fragments of graphite, This carbon is known as graphitic carbon

DIFFERENT VARIETIES OF COMMERCIAL IRON

I Thr~e different varieties of commercial iron are known: and the differentiation is done on the
t basis of carbon present (as impurity) in iron
1. Cast Iron
t Contains the highest proportion of carbon (2-5% ), and as such is the most impure form
of iron
• 2. Steel
Steel lies intermediate between cast iron and wrought iron having carbon content
between 0.1 to 1.5%
3. Wrought iron
It contains the minimum amount of carbon (0.1 to 0.25 %) as impurity

SOLVED PROBLEMS

7 Give one important difference between pig iron (Cast iron), wrought iron and
steel. . I. I t . 2 t 50, rbo I
Pig Iron is the most impure fo_rm of commerc,a iron. t con ains o ,oca n a ong
with varying amounts of Mn, S1, and P . 0
.
Wrought Iron is the purest form of iron. It may contain O to 0.51/o carbon besides

traces of p ~nd Si.rb b tween O 1 to 1 5% i e. between that of pig iron and wrought
Steel contains ca on e · · · •
iron besides small amounts of other metals like ~n, Cr, N1 etc.
8 What is the difference between flux and slag the earthly impurities like sand present
Flux is a substance, which_ is added to( ~e~o::ving a comparatively low melt!ng point.
in an ore by forming a fusible mass. s ag d flux in the extraction of ,ron from
e g limestone ( calcium carbonf ate~ ,s au;uesel~!ss of calcium silicate called(fls~~g). and
· · . It ves sand by arming . b tween limestone , ·
haematite. rem~ . f rmed by the combination e
1
Slag is a glass - like matena_ ~he ore e.g. the slag forme? by
impurities like sand present m f ac~ during the extraction o ,
t:
mbination betw·een
is calcium silicate,

limestone and sand in the blast urn , I

. im urities and s a
CaS103. Relation between_~u:~ slag . . d through reduction
Flux + impun ,e manufacture
. . hoW iron and steel are . . extraction of iron. . .fl°'
9
Give a brief descr1pt1on . n of an oxide o~e ,~ t~s
,place In
a bl~~~ . .-.
of iron or~- - . xample of the ~e~u~~~duction of ~~e~~r~Jt at its widest poin.
The most amp~rtant. e h ematlte.~fe2~ 3· d 6 to 8 n, in d1a
The chief i~ry~?.te 1s ~bout 30 m high an
~i t ~ wh
- ich ts onen
furnace,
 - ~" iuatiori
Course f
or +2 S
ludents
EXTRACTION OF METALS

ALUMINIUM
- Syrnbo1 - THE MOST COMMON LIGHTEST MET Al
Atornic n
• Atorn. urnber Al
ic rnass 13
• Electron·
ic configuration 26 .97

•
2
1 s 2s 2 2p 0 3s 2 3p 1 2, 8, 3
1
KLM (N e1 3s2 3p

•t OCCURRENC
0CCURRENC~ :AND ~~TRACTION OF ALUMINIUM
3s 3p

.
t nature in th f Alumi~1~m does not occur free in nature. Aluminium occurs abundantly in
silicon cons~t ~rm of silicate rocks, clays and other minerals coming next to oxygen and
• The chief . uting about 7.4% of earth's crust.
1 . _minerals of aluminium are as follows:
• · 5
plhcates: Aluminium occurs mostly as silicates, the more important of which are:
potash feldspar: K20. Af 20 3. 6 Si0 2 or K[Af Sb Os]
otash mica: K20. 3Af 203. 6 Si0 2. 2H 20
Kaolin: Af 203. 2Si0 2. 2H 20
2.
Oxide: (Af 203): The most abundant of the oxide minerals of aluminium is bauxite,
A f 203.2H20, which is main source from which the whole of the commercial aluminium
is obtained. Other important minerals are:
Corundum: Natural form of Ae 20 3 (Nearly as hard as diamond)
Ruby: Red form of A£20 3
Sapphire: Blue transparent corundum, Af203
Emerald: Green
On account of their beauty and lustre, these minerals are used as gems. Emery, an
impure form of aluminium oxide, is very hard and is used as an abrasive.
3. Aluminates: Certain metallic aluminates (e.g. of Mg, Fe and Mn) also occur in nature,
and are termed as spinels. Ordinary spine\ is magnesium aluminate.
General formula of spinels is MO.R203, where Mis a bivalent metal (Mg, Fe2+, Mn, Zn)
and R is a tervalent metal (Ae, Cr, Fe 3+)
4. Others: Other naturally occurring aluminium minerals are -
Turquoise: a hydrated basic phosphate having the composition A£P0 4. Ae(OH)3. H20 .
Cryolite: a double fluoride having the composition Na3A£F 6 i.e.(3NaF. AeF 3)
Alunite or Alumstone: K2S04.A€2(S04)3. 4Af(0Hh

EXTRACTION OF ALUMINIUM
Aluminium is now exclusively prepared from the mineral bauxite by an electrolytic process
discovered by the American chemist, Charles Martin Hall. The process involves two distinct
steps:

1.
 I

Foundation c
___ . ourse for +2 Students •f
EXTRACTION OF METALS
. f
impurities must be elimi ,
to corrosion Pu 'f . nated, which otherwise may render the metal brittle and prone 4
· n ication of bauxite is carried out by two different processes.

FLOWCHART FOR THE PRODUCTION OF

ALUMINIUM OXIDE (ALUMINA)
FROM BAUXITE
BAEYER'S PROCESS

/ Bauxite /S odium hydroxide solution

I I
l
DIGESTER
The bauxite dissolves in the NaOH solution under pressure
J
SETTLING TANK
I Undissolved solids removed from the solution
!
PRECIPITATORS .
Aluminium hydroxide added to encourage precipitation of the solution
I
KILN
Precipitated aluminium hydroxide roasted at high tempera ture.
Aluminium oxide (alumina) is made
l
Aluminium oxide ready for electrolytic
extraction of the aluminium
!
Refining of Extracted Aluminium by Electrolytic Proces s
I I
(a) BAEYER'S PROCESS
roaste d
In this process, which is particularly suitable for treating red bauxite is
digest ed
to covert ferrous oxide, if any, into ferric oxide. The roasted ore is then
The
with concentrated NaOH solution in autoclaves under pressure at 130°.
and
aluminium oxide passes into solution partly as sodium meta- alumi nate
partly as colloidal alumina, while ferric oxide, silica etc. remain undiss olved
Af 2 0 3 .3H2 0+2N aOH ~ 2NaAI 0 2 +4H 2 0
Sodium
meta aluminate
e ferric
The solution thus obtained is diluted with water, and filtered to remov
ium
oxide ~nd silica. A s'!1a/l quantitr o~ hydrous aluminium oxide (i.e. alumin
nuclei for
hydrox1d_e~ fr~m a previous o~erat1on 1s added to this liquid (to provide
h
the prec1p1tat1on) and the mixture is agitated for several hours (::::: 36 ours o
)t
t I ·
change so d',um me a-a um1nate to aluminium hydroxide:
NaAeo2 +2H20 Hydrolysis >NaOH+ A e(OH)3
Precip itate
The precipitate of aluminium hydroxide is filtered washe d d. .
2Ae(OH) lg~it~on > A/} O 3H O , an ignited
3~ .+ . •·2
.11, i. • .•.. .." p t 2 3 ~• ,
·f -~
,, " l 1" ~~ .
•. ~"11 :'.~-: ~ ,,
u_re. . ,Jr ~ t .·, .
r ' '•
. t ~J:i-t• ··:· . alumina •- 1ti:;,i.
1
I, :I~ ;,.~ :, I .I

..A
~

Foun d a tion c ours e for+

------ 2 Students EXT RAC TIO N OF ME TAL S

(b)
SER PEC K' S PROCESS .
Th' . . .
is Process of ficati~~ Is employed whe n the baux ite ore co~tam_s a
)S. relatively la e pun
rity. In this process, the ore 1s r:''~ed
With carbonrg amount of silica as an impu gen when alum1rnum
nitride . and heated at 1,80 0°C in a current of nitro
is Produced :
AC2 0 3 + 3C + N 2 ~ 2A eN + 3CO
· g volat1·1 e at
· h bein
• is reduced to silicon whic
The silica that th e bauxI·te contarns •
.
th 1s tempe ra ture, passes off as vapour:
Sio 2 +2 c~ 2c o+ si
ed to aluminium hydroxide:
Aluminium nitride is subsequently hydrolys
A eN+ 3H 20 ~A e(OH) 3 +NH l4
h' .
w 1ch Is filtered, washed and ignited:
2A e(O Hh ~ A e 2 0 3 + 3H 2 0
product in this process is a distinct
Formation of ammonia as a valuable by
advantage.

(c) HAL L'S PROCESS

ted with Na2C03 to bright redness .
In this process the bauxite ore is hea
nature, gets dissolved to form sodium
Alum ina (Al20 3), which is amphoteric in
with water. Fe203 and Si02 are left as
met a-a lum inat e which is then extracted
inso lubl e impurities.
+2H 2 0
Al 2 0 3 .2H 2 0+N a 2 C0 3 ---- -?2 NaA I0 2 +CO 2
solution of sod ium met a aluminate at
On pas sing carbon dioxide through the
ipitate.
323 -33 3 K, Al (OH)3 separates out as prec ~
~
0-- -2A l(0 Hh +Na C0
2Na AI0 2 +CO 2 +3H 2 2 3

hed , and the solu tion of Na 2C0 3 is

The prec ipita tes of Al(OH)3 are was
reci rcul ated afte r concentration.
in a
alu min ium hydrox ide obtaine d by any of the above processes is calcined
The
rotary kiln at 1773 K to get pure alumina.
1773 K Al203 + 3H20
2Al (0H h

IFIED BAUXITE
2. ELECTROLYTIC REDUCTION OF PUR
tically. Difficulty is faced in this process
Reduction of purified alumina is done electroly
due to the reasons as follows:
(i) Pure alumina is a bad conductor of electricity.
The boiling poin t of alum iniu m is 2073 K, while the fusion temperature ~f pure
(ii)
al formed due to electrolysis gets
alumina is 2273 K. As such the aluminium met
vaporised at this temperature.
. rtI (Na ~eF6) and
ture ~ of alum ina, cryo e · . .. Fusion
To obviate these difficulties, a mix
rspar ( CaF ) in the ratio of 1 : 3 ,.: 1 · is used for ~l~ct~~ts~, a -good
I"
fluo
and it ~! 59~be -~,me_
2
/· temper~tu re Rf thi~ mixture is red ~ce d a~·)'}
73 K
conductor of electricity. - ·
 1:A I KACTI ON OF METALS

The electrolytic cell consists of an iron box having dimension of 8ft x 6ft x 6ft
and is lined with about 30 cm wide carbon layer. This carbon layer acts as th~
cathode. The anodes are made up of graphite rods which dip in the fused
mixture of electrolyte . Th~ anodes are ~ovable and can be adjusted by
suspending, raising or lowenng as per requirement. The fused electrolyte is
covered with a layer of coke.

During the process of electrolysis the temperature of the bath Is maintenance

between 1150 - 1225 K. Carbon monoxide and carbon dioxide gases are
fanned during the electrolysis process which happens due to the reaction of
oxygen liberated from alumina and carbon rods .

THE EXTRACTION PROCESS

The electrolyte consists of a mixture of purified bauxite (20 parts), cryolite (60 parts) and
fluorspar (20 parts). Cryolite is added to make a liquid melt with Al203. The electrolysis
is done at about 1150 -1225 K. Fluorspar is added to increase the fluidity of the melt i.e.
to lower its melting point and to decrease its density so that the libered aluminium would
sink at the bottom of the electrolytic cell.

The electrolyte is melted by lowering the anodes and striking an arc between them and
carbon lining of the cell. The anodes are raised after the fusion of the electrolyte has
occurred. The surface of the melt is covered with powered coke to minimize the oxidation of
the anodes during electrolysis.

On passing electric current, electrolysis progresses, liberating aluminium at the cathode and
oxygen at the anode. The molten metal (m.pt. 660° C) sinks to the bottom of the electrolytic
cell and is removed from time to time through a tapping -hole.
The oxygen formed at the anodes attacks them, giving off a mixture of CO and CO , and the
2
oxidation of the expensive anodes is minimized by the layer of coke powder, as
already mentioned.

REACTIONS TAKING PLACE DURING ELECTROLYSIS OF Af20

3
Let us see what reactions take place at the two electrodes. Molten aluminium oxide (Ae 0 )
2 3
contains free aluminium ions, Ae 3 +, and oxide ions 0 2 -. On passing electric current through
molten aluminium oxide, the following reactions take place at the two electrodes.
Ae203 ~ 2Ae3+ + 30 2-
(i) At cathode:
The positively charged aluminium ions, Ae3 + go to the negative electrode (cathode),
where they accept electrons and form aluminium atoms or aluminiu m metal:
Af 3+_ + 3e Reduction Ae
Aluminium Electrons Aluminiu m
1on(from (from
alumina) cathode) atom (Metal)
Aluminium metal is thus fo_r~~~ ·at the cathode. aqd gets :collected at the bottom ofthe
~ tank. .. ,,
,,, 4 ,.
' ';.' t ·
' t.
·:t,,~;~r
1 :·;;!,;, ,,
\l} ~~ ·; ,
,.i,.;·
r. --~;iE' " .-.,.
')
'f -t;:f•1 ~ 'l.
:',j
, •.:;. ~,~.,_~
~{ t.,•,
I f,1
-~~-,~•l";;'- "
•r_
'.
/ V
•• •
f! .. I ""
I,
Ti
~-
'
~·~,Ji .
-.U • f
..
1 ,:.r•
w
,- :
' ..... • -:~,~-
1
Foundation
--- Course for +2 Students EX TR AC TIO N OF ME TA LS

(ii)
At Anode:
), where
The negat' 1 charged oxide ions, 0 2 -, go to the positive electrode (anode
ive Y
the y I bine to form oxygen gas
gen atoms, which in turn com
molec~~=s~lectrons to form oxy

o2- - 2e Oxidation 0
Oxide ion Electrons Oxygen
(from (Given to atom
alumina) anode)
0 +0 ~ 02
Oxyge n ato ms Ox yge n gas
gas reacts
is libe rate d at the carbon anode. Thus liberated oxygen
T~us, oxygen gas in the gradual burning
h the car bon of car bon ano de to form CO 2, which results
wit
aw ay of the carbon anode. at the electrodes:
about the reactions taking place
Th ere is yet another concept
e ionizes as:
As per this concept, the cryolit 3 6F-
Na 3Af F6 ~ 3Na + + 3A e + +

At cathode:
Ae + ions reduce to Ae
3

Ae3 + +3 e- -)A f (At cathode)

At Anode:
F- ions are oxidized to F2
(At anode)
2F - -- )F2 + 2e
liberates oxygen at anode.
Fluorine reacts with alumina and
3 30 2 i
2A e203 + 6F2 ~ 4A f + + 12F - +
into Ae and 02 and liberates Ae.
In this way A f20 3 decomposes

Copper Clamps

Frozen crust of electrolyte

and alum ina

Carbon lining

ina for Extraction of AJuminamium

Fig. Ele ctro lysi s of Molten Alum
. . Th II consists
OF AL UM INIUM lytic cell . e ce
REFINING by Hoope's Process in an electro
Purification of aluminium is done
of three fus ed layers : . fl 'd and
y of Cu, Ae and Si.
(i) The lower anode lay er of the allo uon e,
The mid dle layer con sists of a mixture of cryolite and barium
(ii) .• .,.JJ •. , ... ,
alumini~m metal .
(iii) The upper cathode layer 9f pure
is ma de of i ron J 2
> !,.l qro~~~
i~ed inside with ':if . .;,-s· . ·~·
t . I '" •
f

•
,1'

t
•
•
The
>
~;·
cell
't -
~» •
. . .- -.~ , - ~ -,;
1 ffi · ~·:t -,
.r. •
-•; ·t -
r Foundation Course for
+2 Students
EX TR AC TI ON OF M
ET AL S
On ~l~ctrolysis , alumi
nium ions_from the fus
aluminium metal. At the ed mixture are discharg
same time an equivale ed at ca_thode as_pu~~
electrolyte (middle) lay nt amount of aluminium
er from the lower lay goes into sol~t,on
transferred from the er of alloys. In this wa
lower layer to top lay y pure alumln~~m 1~
copper etc are left behin er through middle lay
d . The aluminium obtai er . The impunt,es 0
ned with this method ha
s purity of 99.9B% .

~. :.. .-, Ff= - Graphite rod

Tappinq hot

Iron cell

Fig : Electro- refining of Carbon lining

Aluminum
FLOW-SHEET OF THE
METALLURGY OF ALUM
INIUM
/Powered Bauxite J--;· !High temp.
====== ~-----11Calcined
J

Ore
jcalcination I
(B) WET (BAEYER) Pro
cess
Digestion with 45% Na
OH sol
(A) Dry Process Fusio at 150° C and under Pre
n with ssure
Na2 CO 3 1100 ° C

Digested with water

(80 °C) and filtered

Filtrate Residue
(Mainly (Red Mud)
NaAeO2) Rejected
Hydrolysis
(5 0- 60 °C)+
CO2
Filter

Filtrate
(Recycled)

Ignition ( 1200°C)

(Electrolysis (Hall and

~ -- -- -- -- -, Heroults' Pr oc es s)
luminium 97%

•· Pure aluminium
'
99.99% . ~ '
I
' I
i
 ZINC :THE METAL USED FOR
GALVANIZATION
Sym bo l Zn
Ato mic Number 30
Ato mic Mass
65 .39
Electron ic configuration
KL M N
2 8 18 2
1s2 2s 2 2p 6 3s 23p 63d 10 4s 2
[Ar] [il l I f J I f J I f ! I t1I ii I i.e.
2
[Ar] 4s 3d 10
4s 3d

Zinc element has two electrons

in the outermost quantum shell,
she ll. The t\-vo electrons of the and 18 in the pe n- ul~ ~:! ~
outermost shell are alone used
are alw ays used together. Henc for valency pu rpo se s an
e the metal is uniformly divale
On acco unt of its small atomic nt. . t th e
volume, the positive nucleus ex
pe riphery of the atom. Hence the ert s a strong inf lue nc e trze d
electrons from the penultimate
for valency purposes. shell are ne ve r u 1 1

OC CU RE NC E:
Ord inarily zinc is found in the com
bined state. Traces of zinc in na
The zinc ores of industrial import tive sta te are als o fou nd ·
ance are :
(i) Zinc blende, ZnS
(ii) Calamine, ZnCO 3
(iii) Franklinite, ZnO. Fe 2O3
(iv ) Zincite, ZnO
(v) Willemite , Zn2SiO4
The first two ores of zinc are by
far the most-important. Zinc ble
.. 'to.-

Be lgi u~ , Burma ~~c.,.J11 India,

!I'
'
~~
nd e, the main ore , is fou nd ir
it i~ _
f9~!
•
,p".
?d
.. • .0
"'.. -\ ' . ..{l: " .• - •
~~

traces in the form of o~ an o-m eta iD.J.

~. ~j.~stha_n (f'.aw~r,_U,daiP,j~p-;~!\ i~,
_ -
alS(? fou n~ i~
lhc cotnpoll!Jd~ :_IO animal cells1
f t;•:Jl-~-\ ! -
 OF METALS
• - - - - - _ _ __ _
_ 10 N
1::_A_1_1_t A_t_;-T

• M E TAL LUR G Y
nl OAI In,
~~~ l~~~~~~ ll~ ~1ouorn ~zloncr zin
• l ho whi ch I Is f .
hl onrto n POrt nnt oro fro m c Is Produced
. rom zinc
ln 1111n o corn 1t1 0 noxt
. from th ese o
• lo llo w l ~A ~~~P ~n res involves the
,
•
N
C O N C E NTRATIO
•
I
W ho n zinc blon·do s usod ch os u ro
and th e
It Is fir st pulv erizede met II n concentrated by the
"f oss " whi h 10 bo
ro th float atio n proc under th
I os eo n describ ed a urgy of copper .
I R O A S TI N G
) . Th reverberatory
(a ) Zinc Biondo (ZnS m
ts ouxsltdfel~ st be roasted In a furnace in a
nv~rt ltl~nf~~
t cu rre nt of ai r to co .
2 ZnS + 3 0 2 ----+ 22 n o + 2S 02
t w h ich Is th . duced to metal by distillation with
carbon
en re

• (b) Calamine (Z n co 3
)
.

• W he n th e or e co
m us t be ca
Zn C O
lc in ed
nsists
to el
of
im
3 -- -- +Z nO +
in
th e ca rb
ate CO 2
CO 2
on
an
at
d
e roasti
m
'
o1
,
s
t
ur
ng
e.
as such is not nece
ssary but the ore
,

carried ou . shelf_burner. This is

provided
e sulphide ore is
T~ e ro as tin
~1th ho_rizo_
~i nc ox 1? e
g of th
n ta l sh el ve s and
IS di sc ha
air-cooled
rg ed co nt in uo us ly
ra
at
ric acid
nk
th
.
in
e
t
1:t~:·
in a ro

.
ta
~~
ry
e
e
ore is fed in at _the
S0
top , wh ile
2 produced in the proc
ess
an uf ac tu re of sulfu
is us ed in the, m
el ti ng ) .
R E D U C TI O N (Sm as ob ta in ed ft . . .
n, _is carried out by he
ating it
n of zi nc ox id e, as tin hg /c alcin at ,?
Th e re du ct io cl os ed retorts m ad
e o ffi: cr ol zinc volatilizes ·
25 % of co al in ay, w en metallic
w ith
O
Z n O + C ~ Zn + C
on is
ab le , as su ch an excess of carb
sily oxidis id ize the
in va po ro us state is ve ry . ea di ox id e, w hi ch otherwise would ox
[Zinc io n of carbon
ce ss ar y to en su ~e th e no n- fo rm at
n_e ox id e:
zi nc ba ck to th e Zn O + C O t mod em
Zn + CO2 ~ ed fo r th is re du ction , but the mos
m ay be us
er en t ty pe s of re du ci ng fu rn ac es w hi ch is highly economic
al.
D iff t P ro ce ss
th e Vertical Retor
pr oc es s us ed is
rangements
R T IC A L R E T O R T PROCESS et re he ig ht co nnected with an ar
VE
rt ic al re to rts of ab
ou t 7 to 8 m
e are made of si
licon carbide
th is pr oc es s ve an d ro as te d or d
In
us fe ed in g of po w de re d co ke or de r an d th ey are able to withstan
fo r co nt in uo s of high
ch ha ve re fr ac tory characteristic us in g Pr od uc er gas (contains CO
:
b ri ck s w hi ternally heated
s up to 13 00 ° C. R et or ts ar e ex ie s of hydrocarbons & C 2
O ). A sh
te m pe ra tu re al l qu an tit
: 50 - 55% H 2
:10 - 15% and sm n provided at the bo
tto m . The
25 - 30 % , N h an ex te ns io
2
m ov ed throug ense r by a
uc ed in th is pr oc es s ca n be re th e pr oc es s ar e carried to the co nd
pr od pr od uc ed in d constant su ctio
n is appUed
ur an d ca rb on m on ox id e th e re to rt an
zi nc va po at th e bo tto m of
~h't~' C9 ndenser th ro
ugh
rr en t o f pr od uc er ga s ad m itt ed di ca lly ta pp ed of f ff9 ~
cu pe rio
en se r. Th e Z!nc is, J\ ' •
;. • _..

to th e ou tle t of th e co nd ~
' I
' ~~ · ·• •
:i~ '.:. ·
> } "'i
-~ : · .
\
• 't
1 -~·

the tap~hole.
 AL S
Stu de nts EX TR AC TI ON OF M ET
=o un da tio n Co urs e for +2

Po wd ere d Or e Po wd ere d Or e
/ Zin c ble nd e (Zn S) Ca lam ine (Z nC 0 3 )
Co nc en tra tio n

l (F rot h Flo ata tio n

. - - - - - - -_ _P _ ro_ce ss )
Co nc en tra ted Or e /
Co nc en tra ted Or e

Ca lci na tio n
S0 2 ----j Ro as tin g (fo r rem ov al of CO2
an d mo ist ure )
Ro as ted Ma ss
(M ain ly Zn O)
Ca lci ne d Ma ss
Reduction wit h Zn O
Carbon

SP EL TE R
Impure Zin c
Refining

Electro-refining
Th erm al refining ( electrolysis of Zn S0 4 so
lution
(II)
ing
(I) (D ist illa tio n wit h acidified with dil. H2S04, us
Zn
a little KNO; anodes of sp elt er { impure
zinc
ingots) and cathode of pure
rods) te .
/ Pu re Zin c l
03 is do ne to co nv er t ar senic to non-volatile ar se na
Ad di tio n of sm all ~ttam,ty
of KN