IOC Metallurgy E

JEE (MAIN+ADVANCED)
GENERAL PRINCIPLES & PROCESSES OF

ISOLATION OF METALS (METALLURGY)
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CONTENT
S.No Pages
1. Metallurgy 02 – 24
2. Exercise-1 25 – 44
3. Exercise-2 (Section-A) 45 – 46
4. Exercise-2 (Section-B) 47 – 49
5. Exercise-3 50 – 55
6. Answer Key 56 – 59
Metallurgy
METALLURGY
INTRODUCTION
(1) Metal found in earth crust in form of mineral.
(2) Abundance of elements in earth crust O > Si >Al
(3) “Ore” is the mineral form, from which the metal can be economically and conveniently extracted.
(4) Commerically value less material found in ore is called Gangue or matrix.
(5) Every mineral is not an ore but every ore is a mineral.
(6) Insoluble compounds are found in earth crust.
(7) Nitrate ore does not found because all nitrate are water soluble.
(8) Group 16 element are known as “Chalcogen” (ore forming) because most of the oxygen containing
compounds and sulphides are water insoluble.
(9) Heavy d-block metals generally form sulphide ore because polasrising power of heavyd-block metals is
high and polarsabilityof sulphide is high.
Type of Ore :
(a) Native ores : They contain metal in free state and are found along with rock or alluvial impurities like
clay, sand etc.
Example : Silver, gold, platinum, mercury
(b) Oxygen containing ores : Theyores consist of oxides or oxysalts (e.g. carbonates, phosphates, sulphates
and silicates) of metals.
(i) Oxide ores : Haematite (Fe2O3), Bauxite (Al2O3.2H2O), Cassiterite(SnO2) etc.
(ii) Carbonate ores : Lime stone(CaCO3), Dolomite (CaCO3.MgCO3), Calamine (ZnCO3) etc.
(iii) Sulphate ores : Epsom (MgSO4.7H2O), Gypsum (CaSO4.2H2O), Anglesite (PbSO4) etc.
(iv) Phosphate ores : Hydroxyapatite [Ca5(PO4)3·(OH)], Chlorapatite [3Ca3(PO4)2.CaCl2] etc.
(v) Silicate ores : Asbestos or Calcium magnesium silicate (CaSiO3.3MgSiO3),
Talc (Mg3(Si4O10)(OH)2
(c) Sulphide ores : These ores consist of sulphides of metals.
Example : Iron pyrite (FeS2), Galena(PbS), Zinc blends (ZnS), Cinnabar(HgS)
(d) Halide ores : These ores consist of halides of metals.
Example : Horn silver (AgCl), Carnallite (KCl.MgCl2.6H2O), Fluorspar (CaF2) etc.
The step involved in extraction of metal from its ores in profitable is called metallurgy.
(A) Generally, metals are found in combined state. In combined state, positive charge present on metal. In
pure metal oxidation state of metal is zero. Hence in metallury reduction of metal is necessary step. On
the basis of reduction metallurgy can be
Metallurgy
Pyrometallury Hydro metallurgy Electrometallurgy

(thermal treatment) (use of aqueous chemistry) (use of electrodes)
(i) Hydrometallurgy : It involves reduction of metal in aqueous medium bymore electropositive
metal. This process is used for least reactive metals, Ag, Au, Pt and also low grade ore of Cu
and Hg. Metals having reactivity greater than H+ can be extracted by hydrometallurgy
(ii) Pyrometallurgy : If heating effect is involved in extraction of metal from its oxide in presence of
suitable reducing agent then it is named as pyrometallurgy.
Example : Zn, Cr, Fe, Mn, Sn, Pb, Cu, Hg
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Metallurgy
(iii) Electrometallurgy : When electrolytic process is involved in extraction of metal then it is named
as electrometallurgy. It is very expensive process, so it is the last option for reduction. Highly
reactives-block metal andAluminium can’t be reduced in aqueous medium and by any reagent
beacause compound with reagent, hence they are reduced in molten state by electrolytic
reduction.
GENERAL STEPS INVOLVED IN METALLURGY
ORE
(Crushing and Grinding)
Gravity separation
Leaching Chemical Physical Magnetic separation
Froath flotation
Concentrated Ore
Calcination Roasting
Metal oxide (i) Metal displacement
(i) Cupellation (ii) Self reduction
(ii) Polling
(iii) Bessemerisation (iii) Carbon/CO reduction
(iv) Zone Refining (iv) Reduction using active metal
(v) Vapour phase refining (v) Electrolytic reduction
(vi) Distillation Impure metal
(vii) Amalgamation (vi) Reduction by hydrogen
(viii) Liquation
(ix) Electrolytic Refining
(x) Parke's process
Pure metal
(xi) Pattinson's process
COMMON STEPS INVOLVED IN METALLURGY

(I) CRUSHINGAND GRINDING (PULVERIZATION)
Handpicking : To pick up selective pieces of ores.
Operation in which size reduction of large lumps to small pieces followed byfinelygroundmaterialisdone
bythe use of crushers and grinders.
(II) CONCENTRATION (DRESSING) OF THE ORE

Operation in which the removal of impurities (gangue) from ore by the following methods.
(1) PHYSICAL PROCESS
(a) Levigation or Gravity separation :
 This method is based on the difference in densities of the ore gangue particles.
 The powdered ore with gangue particles is introduced in the running stream of water.
 Lighter impurity particles washed off with water and heavier ore particles settle down at the bottom.
Example : Generally oxides & carbonate ores are concentrated by this method.
Metallurgy
Crushed
Powdred
ore
ore
Hopper
Water
Corrugated
boards
Gangue
Sloping
Power current table
of water conc. ore
Gangue with water
Figure : Hydraulic Washer Figure : Wilfley Table
(b) Magnetic separation
Then one of the component in powdered ore either ore or impurities are magnetic and other is non
magnetic then ore is concentrated by magentic separation.
Example :
e.g.-(i) In metallurgy of Cr from Chromite ore(FeO.Cr2O3).
Ore  magnetic
Impurity  non magnetic
e.g.-(ii) In metallurgy of Sn (tin stone)
Ore  non magnetic (SnO2)
Impurity  wolfmarite (FeWO4 + MnWO4) magnetic
e.g.-(iii) In metallurgy of Mn from Pyrolusite ore(MnO2).
Ore  magnetic
Impurity  non magnetic
Magnetic
Ore
roller
Magnetic Non Magnetic

impurities ore particles
(c) Froath floatation process
Metallurgy
 It is employed for sulphide ores.

 It is based on the differential wetting characteristics of the ore and gangue particles with water
and oil and adsorption
 Ore particles are wetted by oil while gangue particles are wetted by water
 Ore particles raised to the surface along with air bubbles and collected at the surface where
as gangue particles are wetted and settled down at the bottom of the tank.
 Reagents used a froathing agents (pine oil), collectors (sodium ethyl xanthate and potassium
ethyl xanthate),Activators (copper sulphate) and depressors (sodium cyanide, alkali).
Collectors :
These compounds adsorb themselves on polar groups to grains of ores and thus derive them on the
surface to pass on into the forth.
Example : sodium ethyl xanthate and potassium ethyl xanthate.
Activators – To increase adsorption power of ore such compound are used example copper sulphate
(activator) which activates the floating character of ZnS particles
Depressants – When a sulphide ore contain impurity of other metal sulphide to separate the depresent
is used.
Example : Sodium cyanides is used the depressants when Galena (PbS) contain impurity of (ZnS)
(2) Chemical method of concentration :
Leaching : It involves dissolution of metallic ore in a suitable reagent in which metallic ore is soluble
and impurities are insoluble.Selective dissolution of ore in strong reagents where as gangue particles
are undissolved and gets separated. (Hydrometallurgy)
Example :
(i) Leaching of alumina from red bauxite :
Baeyer’s process :
If Fe2O3 is major impurity - Red bauxite
Al2O3(s) + 2NaOH(aq) + 3H2O(l)   2Na[Al(OH)4](aq) + Fe2O3 

The aluminate in solution is acidified adding acid and hydrated Al2O3 is precipitated.
Low temperatur e
2Na[Al(OH)4](aq) + CO2     Al(OH)  + Na CO (aq)
Seeding 3 2 3
white ppt
Hydrated alumina is filtered, dried and heated to give back pure Al2O3

Al(OH)3   Al 2 O 3 (s) + 3H2O
white ppt impure
(ii) MacArthur-Forest cyanide process :

In the metallurgy of silver and gold, the respective metal/ore is leached with very dilute solution of
NaCN or KCN in the presence of air (for O2) from which the metal is obtained by displacement
reaction.
(a) from native Ag or Au
4M(s) + 8CN–(aq) + 2H2O(aq) + O2(g)  4[M(CN)2]–(aq) + 4OH–(aq)
[M = Ag or Au]
2[M(CN)2]–(aq) + Zn(s)  [Zn(CN)4]2–(aq) + 2M(s) 
(b) from silver glance
Ag2S(s) + 8CN–(aq) + 2H2O(aq) + O2(g)  4[M(CN)2]–(aq) + 4OH–(aq) + SO42–
[M = Ag or Au]
2[M(CN)2]–(aq) + Zn(s)  [Zn(CN)4]2–(aq) + 2M(s) 
Metallurgy
Other example :
(i) Halls’ method :
If Fe2O3 is major impurity –Red bauxite
- bauxite ore is fused with Na2CO3
- Al2O3.2H2O + Na2CO3Fuse  2NaAlO2 + CO2+ 2H2O
- 2NaAlO2 + 3H2O + CO250ºC  2Al(OH)3 + Na2CO3

- 2Al(OH)3  Al2O3 + 3H2O
(ii) Serpeck’s method :
If SiO2 is major impurity - white bauxite
- Al2O3 + 3C + N2  1000ºC   2AlN + 3CO
digest
- AlN + 3H2O    Al(OH)3 + NH3
- SiO2 + 2CO  2CO2 + Si
- 2Al(OH)3  
 Al2O3 + 3H2O
(III) WORKING OF THE CONCENTRATED ORE

Conversion of the concentrated ore into its oxide form
(a) Calcination :
 Ore is heated in absence of air to remove water or CO2 from hydrated oxides or carbonates
respectively.
 Process temperature is below the melting points of treated ores.
 During calcination moisture, volatile impurities are removed there by ore becomes porous.
Example : 
Al2O3.2H2O  Al2O3 + 2H2O

2Fe2O3.3H2O  2Fe2O3 + 3H2O

CaCO3  CaO + CO2

MgCO3  MgO + CO2
(b) Roasting :
 Ore is heated strongly with other substances, usually with oxygen.
 Employed for sulphide ores.
 Process temperature is below the melting points of treated ore.
 Chemical conversion of ore is takes place.
 Some of the impurities removed as volatile substances.

S + O2  SO2 

4 As + 3O2  2As2O3 

P4 + 5O2  2P2O5 
Example :
(i) Conversion of metal sulphides into oxides.

2 ZnS + 3O2  2 ZnO + 2SO2
2 PbS + 3O2   2 PbO + 2SO2
(ii) Metal sulphides are converted into sulphates.
PbS + 2O2  PbSO4

ZnS + 2O2  ZnSO4

Metallurgy
(iii) CuFeS along with SiO2 is heated in excess of air in a reverberatory furnace.
2CuFeS2 + O2  Cu2S + 2FeS + SO2
2FeS + 3O2  2FeO + 2SO2 (major oxidation)
2Cu2S + 3O2  2Cu2O + 2SO2 (minor oxidation)
Cu2O + FeS  Cu2S + FeO
Charge
hooper Hangers Charge
Tie Rod hooper
Air & Oil

Magnesite
Furnace charge
Silica
Reverberatory Furnance
Side reactions :
S + O2  SO2  ; 4As + 3O2  2As2O3  ; 4Sb + 3O2  2Sb2O3 
Volatile impurities are removed in this step.
(IV) CONVERSION OFTHE OXIDE TO METALLIC FORM (REDUCTION PROCESS)

The roasted or calcined ore is converted into metallic form through reduction by using different reducing
techniques which will depends upon the nature of the ore, some of the methods are mentioned below
Li
K
Na Electrolytic reduciton
Mg
Al
Mn
Zn Alumino thermite reduction
Cr
Fe C/CO reduction
Sn
Pb
Cu Self reduction
Hg
Ag
Au Hydrometallurgical reduction
Pt
* SMELTING :
Phenomenon of slag formation by combining flux with impurity is called smelting
Flux + impurity  Slag (smelting)
(basic or acidic)
Metallurgy
 Selection of flux depends upon nature of impurity present. Its impurity is acidic or
basic flux is employed and vice versa.
 Smelting is usually carried out in blast furnaces or reverberatory furnace.
Flux : Additional substances which are used during metal extraction to remove acidic or basic
impurity are called flux depending upon nature of impurity flux are of two types.
(i) Basic flux : It is used to remove acidic impurity
eg. : CaO, MgO, CaCO3, MgCO3, FeCO3 etc.
(ii) Acidic flux : It is used to remove basic impurity
eg. : SiO2, B2O3, P2O5, Na2B4O7(Borax) etc.
ELLINGHAM DIAGRAM
The changes in Gibbs energy that occur when one mole of oxygen is used may be plotted against
temperature for a number of reaction of metals to form their oxides. Such a graph is shown in Figure
below and is called an Ellingham diagram for oxides. Similarly, we can plot Ellingham diagrams
for halides.
 Thermodynamic Principles :
Consider a reaction such as formation of an oxide.
2M(s) + O2 (g)  2MO(s)
In this reaction, the randomness of the system decreases because gases have more random than solids.
Hence, S for this reaction is negative. Thus, if temperature is increased then TS becomes more
negative. Since TS is subtracted in equation, G becomes less negative.
+ve T(K) (TS >H) T(K)

0 0
–ve
H (H > TS) BP
G G MP
Metallurgy
On the other hand, if S is positive, on increasing the temperature the value of G decreases and
becomes more negative. For example, in the reaction, 2C(s) + O2 (g) 2CO(g), S is positive
and G decrease and becomes more negative as the T increase.
The Ellingham diagram for oxides show the following important features :
(i) Ellingham diagram normally consist of plots of G° vs T for the formation of oxides of elements, i.e. for
the reaction.
(ii) The graphs for metal oxide have slope upwards because the change in Gibbs energy becomes less
negative with increase in temperature.
(iii) Each plot follows a straight line unless there is some change in phase.
(iv) When the temperature is increased, a point will be reached when the line crosses G = 0 line. Below this
temperature the fG° of oxide is negative and hence the oxide is stable.Above this temperature fG° of
the oxide is positive and hence the oxide becomes unstable and decomposes on its own into metal and
oxygen.
Types of Reduction :
(a) Hydrometallurgy(Metal Displacement Method)
 Process in which more electropositive metal displace less electropositive metals from salt solution.
 First the concentrated ore is dissolved in strong reagent and remove insoluble precipitates.
 Now the metal is precipitated by addition of more electropositive metal.
 The fuel cost is nil in this process because the reduction process takes place at room temperature
or slightly higher temperature.
Example :
Using this process Ag, Au and Cu are precipitated from their respective solutions as follows.
Ag2S + 4 NaCN   2 Na [Ag (CN)2] + Na2S
sodium dicyanoargentate (I)
2 Na [Ag (CN)2] + Zn  Na2 [Zn(CN)4] + 2 Ag 
Note : This type of precipitation process is called cementation.
(b) Reduction by heating in air (Auto-reduction) /Self reduction

 Employed for metals of less activity, such as Hg, Cu and Pb
 Due to unstable nature in the oxide form at high temperature, no reducing agent is required for their
reduction..
Metallurgy
Example :
(i) Redcution of Copper matte Bessemerisation (Self Reduction) :
2FeS + 3O2  2FeO + 2SO2
FeO + SiO2  FeSiO3 (Slag)
2Cu2S + 3O2  2Cu2O + 2SO2
Cu2S + 2Cu2O  6Cu + SO2 (Self reduction)
Impure copper obtained has blister appearances and therefore called Blister copper.
(ii) Galena, after concentration by Froth-floatation process, is roasted in air to form PbO and PbSO4.
The unchanged galena then brings about the reduction of PbO and PbSO4 to Pb metal (auto
reduction).
Heat
3PbS + 5O2  2PbO + PbSO4 + 2SO2 (Partial Rosting)
Roasting
Heat Heat
2PbO + PbS   3Pb + SO2 ; PbSO4 + PbS   
Auto reduction
 2Pb + 2SO2
Auto reduction
PbO  PbSiO 3 CaO

 SiO 2   ( more basic )
  CaSiO 3  PbO Self
 reduction
 Pb
( Amphoteric )
(c) Reduction by Carbon / Carbon Mono oxide :

The oxides of less electropositive metals like Pb, Zn, Fe, Sn, Cu etc. are reduced by strongly heating
with coal or coke.
C//T1
high temp. M + CO
Metal oxide
CO//T2
M + CO2
low temp.
Example :
(i) Carbon reduction of ZnO (Balgian process) :
Roasted ore is heated with coke and lime (CaO) in a vertical fire clay retort.
C 1400C
ZnO  C 1100
   Zn   CO
( R .A ) ( vapour )
CaO + SiO2 fuse

 CaSiO3 (in this way formation of ZnSiO3 is prevented by lime)
(ii) Reduction of Fe2O3 in Blast Furnace :

(Fe2O3 ore + lime stone + coke) is introduced into blast furnace and following
changes take place.
Metallurgy
Figure : Blast Furnace

 Combustion zone (1500 - 2000°C)
(Combustion zone) a blast of dry preheated air is blown into the furnace from near the bottom of
the furnace. Near the bottom, the preheated air comes in contact with the falling coke and combustion
of coke into CO2 takes place.
C + O  CO2 H = – 393.5 kJ
CO2 produced in the combustion zone rises up and meets with more coke in fusion zone and gets
reduced to CO.
CO2 + C  2CO H = + 163.0 kJ
 Reduction zone (200 - 700°C)

Near the top of the furnace (reductio zone), the temperature varies from 250 - 700°C. Here the oxide
ore (Fe2O3) is reduced to spongy iron with the help of uprising vapours of CO produced in the zone of
fusion.
Fe2O3 + 3CO 400  700C
 2Fe  3CO 2
(spongy iron )
Metallurgy
Actually above reduction, takes in 3 steps :
3Fe2O3 + CO  2Fe3O4 + CO2 
Fe3O4 + CO  3FeO + CO2 
FeO + CO  Fe(spongy iron) + CO2 
Any Fe2O3 which escapes from reduction in reduction zone is reduced in fusion zone.
 Slag formation zone (700 - 1200°C)

In the mid of the furnace (slag formation zone) where the temperature varies from 700 - 1000°C, lime
stone(CaCO3) present in the charge decomposes into CaO and CO2.
CaCO3  ,1000C
 CaO + CO2
CaO combines with the impurity of SiO2 and forms a fusible slag of CaSiO3. Thus CaO acts as a basic
flux.
CaO(basic flux) + SiO2(acidic impurity)  CaSiO2(slag)
Slag is lighter than the molten iron. It moves down and floats over molten iron. This region where slag is
formed is called slag formation zone.
 Fusion zone ( 1200 – 1500°C)

Since the reduction of CO2 to CO is an endothermic reaction (heat is required), temperature is de-
creased to about 1500°C. Fe2O3 is reduced to Fe which might not have been reduced in the reduction
zone.
Fe2O3 + 3C  2Fe + 3CO
Impurities are also reduced and get mixed up with molten iron.
MnO2 + 2C  Mn + 2CO
2P2O3 + 10C  P4 + 10CO
SO2 + C  S + 2CO
SiO2 + 2C  Si + 2CO
Spongy iron produced in the reduction zone melts here and gets impured is called pig iron, while slag
being lighter floats over the molten iron and thus prevents oxidation of Fe by blast of hot air.
(iii) Carbon Reduction of Black tin :

The black tin is mixed with anthracite coal (R.A.) and heated to about 1300°C. If SiO2 is
present as impurity then CaO is added as flux.
1
SnO2 + 2C 1300 C
   Sn + CO + 2 O2
Above reaction occurs in two steps
1
SnO2 1300
 C
  SnO + 2 O 2
SnO + C 1300C
   Sn  CO 
(impure)
CaO + SiO2 fuse

 CaSiO3
SnO  SnSiO 3 CaO
 SiO 2   ( more basic )
  CaSiO 3  SnO carbon
 reduction
  Sn
( Amphoteric )
Metallurgy
(d) Reduction using more active Metal

(i) ByAluminium (Alumino-thermic reduction)
CaF2 Mg ribbon
Mg dust
+BaO2
sand
 Aluminium acts as reducing agent due to its high electropositive nature.

 Oxides such as Cr2O3, Mn3O4 are reduced by this method
 The process is also known as “Gold Schmidt thermite process”.
 3 parts Fe2O3 and 1 part Al is called thermite mixture , used to weld / repair of rail track.
(ii) Kroll Process :


TiCl4 + Mg / Na  Ti + MgCl2 / NaCl
(e) Electrolytic reduction (Electro-metallurgy)

 Employed for highly electropositive metals such as Na, K, Ca, Mg etc.
 These metals are extracted by the electrolysis of chlorides in fused state except Al and
Be.
Example :
(i) Electrolysis of fused Alumina (Hall-Heroult method)
Cathode : Iron-tank lined with carbon bricks
Anode : carbon
Electrolyte : Molten [Al2O3 (5%) Na3 AlF6 (85%) + CaF2(5%) + AlF3(5%) ]
Temperature  1100°C
O2 is liberated at anode and Al collects at the bottom.
(+ve graphite
Copper Anode)
clamp Cathod
Molten : Al 2O3 + Na 3AlF6
Molten
aluminiun Carbon lining
(Cathode)
Carbon
anode
Hall Heroult process
Reactions : Na3Al F6  3NaF + AlF3

AlF3 Al3+ + 3F¯
At anode : Al2O3 + 6F¯  2Al F3 + 3/2 O2 + 6e–
At cathode : 2Al3+ + 6e–  2Al
Metallurgy
3
Al2O3 + 6F  2AlF3 + O2 
2
1
C + O  CO
2 2
1
CO + O  CO2
2 2
CO, CO2 and small quantities of fluorocarbons are evolved at anode.
Anodes are periodically changed as they are consumed by oxygen liberated at anode.
(ii) EXRACTION OF SODIUM (Down’s cell process) :

Sodium metal is isolated by the electrolyisis of molten mixture of about 40% NaCl and 60%
CaCl2 in a Down’s cell method. This mixture melts at about 600°C compared with 803°C for
pure NaCl.There are three advantages of lowering the temperature of melt.
 It lowers the melting point of NaCl.
 The lower temperature results in a lower vapour pressure for sodium, which is important as
sodium vapour ignites in air.
 At the lower temperature the liberated sodium metal does not dissolve in the melt, because if it
dissolved it would short circuit the electrodes and thus prevent further electrolysis.
Molten Molten
sodium Chlorine sodium
out out out
~ ~~ ~~~~ ~~ ~ ~ ~~~ ~ ~~~

Molten
Cl2 electrolyte
Na Na
Anode Cathode
Metal gauze
Downs cell for the production of sodium

+ – Electrolysis
2Na (l) + 2Cl (l) 2Na(l) + Cl 2
Reduction at cathode
Oxidation at anode
(iii) Electrolysis of fused anhydrous MgCl2 :

Magnesium chloride obtained by above methods is fused with sodium chloride (NaCl) and
Calcium chloride (CaCl2) in the temperature range of 972-1023 K. The molten mixture is
electrolysed Magnesium is liberated at the cathode (iron pot) and chlorine is evolved at graphite
anode.
700°C
MgCl2 Mg2+ + 2Cl–
electrolysis
Metallurgy
+
Porcelain
hood graphite node
exit for chlorine
inert gas inert gas
(coal gas)
magnesium
Molten Electrolyte
Iron cell
At cathode : Mg2+ + 2e–    Mg(highly pure)
Re duction
oxidation
At anode : 2Cl–   Cl2 + 2e–
(iv) EXTRACTION OF POTASSIUM :
Similar electrolytic cell is used to obtain potassium metal by electrolysing fused KCl. However,
the cell must be operated at a higher temperature because the melting point of KCl is higher but
less than that of NaCl and this results in the vaporization of the liberated potassium. In this
modern method, molten KCl is reduced by sodium vapour at 850°C in a large fractionating
tower. This gives K metal of 99.5% purity.
Na + KCl NaCl + K(vapour)
(V) REFINING OR PURIFICATION
 The metals after reduction process consists of number of impurities like Si, P, slag, oxides, other
metals etc.
 Removal of all these impurities to get pure metal is called as refining.
(a) Distillation
 This is based on difference in boiling points of metals and impurities.
 Employed for low boiling point metals like Zn, Hg etc.
 Impurites have less melting point than pure metal.
(b) Amalgamation
Nobel metals ores likeAg,Au, Pt in finely powdered state are mixed with water to form slurry. The
slurry is then flown over Cu or brass plates coated with Hg arranged in slanting position. The metal
particles forming amalgam with Hg are retained on these plates. The amalgam is scrapped off and then
distilled in iron retorts where Hg distillates over leaving free metals. Hg vapours
Hg Vapours
Ore + Hg Amalgam distilled
Metal
(c) Liquation
 This is based on the principle of difference in melting points of metal and impurity.
 Employed for purification of low melting point metals like Pb, Sn etc.
(d) Cupellation
It is oxidative refining, in this process a impure sample of metal (say Pb inAg) is fused in a bone ash
crucible (Cupel) on the hearth of furnace in the blast of air. In presence of hot air Pb form volatile oxide
while Ag do not form oxide at temperature above 300°C. The impurity (Pb) present is oxidized and
blown away with air. Some PbO is absorbed by Cupel.
Hot air
PbO(g)
Cupel Ag-Pb
Metallurgy
(e) Polling
The impure metal containing oxides as impurity can be purified by this method. The molten impure
metal is stirred with green poles of wood. The green poles of wood release the hydrocarbon gases
which reduce the oxide impurities. This method is especially used in the purification of copper (old
method).
Reduced metal contain impurity of S, C, As, Te in refining process there impurities are converted
into oxides.
Fe O
2 FeO 
 FeSiO3
S CO
2  SO2 
As O
2 As2O3 
C O 2 CO2 
There impurities are generally present in Cu, Sn, Pb so, in presence oxygen some of the metal also
get oxidized into this oxides.
Cu  Cu2O Sn  SnO2 Pb  PbO
To reduce metaloxide into metal fresh green pole is used in molten metal, which contain impurities
of its oxide. Fresh green pole produce CH4 which act as reducing agent for metal oxide.
Fresh green
pole
Molten CH4
metal
Cu2O CH
4  Cu + CO/CO2 + H2O
SnO CH
4  Sn + CO/CO2 + H2O
PbO CH 4  Pb + CO/CO2 + H2O
(f) Bessemerisation (Oxidation process) :
 This is a selective oxidation method.
 Used for refining those metals in which the impurities have greater tendency to get oxidised than
the metals itself.
 The impurities converted into oxide & skimmed off from the metal.
 The impure metal is heated in a furnace and a blast of compressed air is blow through the molten
mass. The impurities get oxidised. For example, the molten pig iron is taken in a bessemer converter
and compressed air is passed which oxidises the impurities.
2Mn + O2  2MnO Converter
Si + O2  SiO2 Flux lining
2C + O2  2CO
MnO + SiO2  MnSiO 3
(slag )
Hot Air + SiO2
Molten matte +Sand
Bessemer converter of copper
Metallurgy
(g) Zone Refining :

This method is based on the principle that the impurities are more soluble in the melt than in the
solid state of the metal. This process depends on phase rule and fractional crystallisation.
 A circular mobile heater is fixed at one end of a rod of the impure metal. The molten zone moves
along with the heater which is moved forward. Phase rule explains that impurities are more soluble
in Molten metal in comparison of solid metal.
 As the heater moves forward, the pure metal crystallises out of the melt and the impurities pass
on into the adjacent molten zone.
 The process is repeated several times and the heater is moved in the same direction. At one end
impurities get concentrated. This end is cut off.
 This method is very useful for producing semiconductor and other metals of very high purity.
Example Germanium, Silicon, Boron, Gallium and Indium.
Circular
heater
Recrystallized impure
pure germanium germanium rod
Direction of travel
Molten zone of heater molten zone
(Containing impurities) and impurities
Zone refining of germanium metal
(h) Vapour phase refining

 Employed to get metal in very pure form in small quantities.
 In this method, the metal is converted into a volatile unstable compound (e.g. iodide), and impurities
are not affected during compound formation.
 The compound thus obtained is decomposed to get the pure metal.
Van-Arkel process :Employed for purification of metals like Titanium, Zirconium, Hf and Boron.
523 k
Ti(s) + 2I2(g)   TiI4(g)
Impure
1700 k
TiI4(g)   Ti (s) + 2I2(g)
Mond’s process :
Nickel is purified by using CO gas. This involves the formation of nickel tetracarbonyl.
330  350 K  470 K
Ni  4CO      Ni (CO ) 4 450
 
 Ni  4CO
Im pure nickel vapour Pure nickel
(i) Park’s Process :

 This process is used for Pb containing impurity of silver. It is called “Desilverization Process”.
 This process depends on partition coefficient (solubility of a metal in different solvents.)
 This process also depends an alloy formation tendency of d-block metals.
 Pb form alloy with Ag but not with Zn whileAg form alloy with both Zn as well as Pb, but in Zn, Ag is
300 times more soluble in comparison to that of, in Pb.
Layer
Molten Zn of Zn-Ag
Pb - Ag Zn - Ag after Distillation
seperation Zn - Ag Zn(g) + Ag
(molten) Pb (pure)
Metallurgy
(j) Pattinsons Process :

 Desilverization process of impure Pb.
 This process depends on difference in melting point of pure metal and impure metal.
 Impure Pb is heated above 327°C on cooling temperature is maintained between 302°C and 340°C.
So, that pure Pb can be solidified in mixture while impure metal is present in molten phase.
 After several repetitions of this process impure mixture contains major amount ofAg, Ag is recovered
by cupellation.
(k) Electro-refining
 Employed for refining of highly electro positive metals likeAl, Cu,Ag, Zn, Sn, Pb, Cr, Ni etc.
 Impure metal is made as anode, thin pure metal sheet is kept as cathode and the electrolyte comprising
with soluble salt solution of the metal.
 On passing the electric current, pure metal from the anode dissolved and is deposited on the cathode.
 The soluble impurities goes into the solution (remains in the solution after the completion of refining) while
the insoluble impurities settle down below the anode as “anode mud”
 
Anode
(impure copper) Cathode
(pure copper)
Anode mud
Electrolyte
(Copper sulphate solution)
Electrolytic refining of copper
S.No. Metal Anode Cathode Electrolyte

(Impure metal) (Pure metal)
1. Au Impure Au Pure Au AuCl3 + H[AuCl4]+ HCl
2. Ag Impure Ag Pure Ag AgNO3 + dil. HNO3
3. Cu Impure Cu Pure Cu CuSO4 + dil. H2SO4
4. Pb Impure Pb Pure Pb PbSiF6 + H2[SiF6], Gelatin
5. Sn Impure Sn Pure Sn SnSO4 + H2SO4
6. Cr Impure Cr Hg Cr2(SO4)3 + dil. H2SO4
7. Mn Impure Mn Hg MnSO4 + dil. H2SO4
8. Zn Impure Zn Al ZnSO4 + dil. H2SO4
9. Al Impure Al(Molten) Pure Al(Molten) Na3 AlF6 + BaF2
Metallurgy
Other example:
 Electrolytic refining (Hoope’s process), three layers process.
Cathode : Carbon electrodes
Anode : Fe tank lined with carbon bricks
Electrolyte : Na3AlF6 + CaF2
Impure Al
Pure Al Cathode
Iron cell Na3 AlF6 + CaF2
Cu, Al, Si alloy anode Carbon

lining
Hoope’s process for purification

of aluminium
Bottom layer : Impure aluminium consists of Cu, Si etc. in molten state as anode.
Middle layer : Molten mixture of Fluorides of Na, Ba, Al andAl2O3 as electrolyte.
Top layer : Pure molten aluminium as cathode.
On passing the current,Al is deposited at cathode from the middle layer and an equivalent amount ofAl
from the bottom layer moves into the middle layer leaving behind the impurities.
Metallurgy
(I) EXTRACTION OF GOLD

Important ores of gold are :
(i) Calaverite,AuTe2 (ii) Sylvanite , AuAgTe2 and (iii) Bismuth aurite, BiAu2
  
Au MacArthur Refining by (i) Electrolyt ic refining method
Native ore
  Impure Au
Forest cyanide process
         Pure Au
(ii) Amalgamation
(II) EXTRACTION OF SILVER

(a) Ores : Silver glance or argentiteAg2S, Ruby silverAg2S. Sb2 S3, Horn silverAgCl.
(b) Process : Cyanidation or Mac-Arthur-Forrest cynide process
Silver glance Froath floatation
Solution
Leaching consists of
Na[Ag(CN) 2]
Displacement
Ag
ImpureAg is purified by Electrolytic refining method or byAmalgamation.
(III) EXTRACTION OF COPPER

(a) Ores : Copper pyrites CuFeS2 ; Cuprite or ruby copper Cu2O ; Copper glance Cu2S ; Malachite Cu
(OH)2.CuCO3 ; Azurite Cu (OH)2.2CuCO3.
(b) Process: Copper pyrite
Froath
floatation
Roasting Smelting matte

(blast furnace) (Cu2S + FeS)
98% 2%
Air, silica
Bessemerisation Blister Cu
(Bessemer converter)
Refining Pure Cu
slag
(i) Poling
(ii) Electrolytic refining
Metallurgy
Low grade copper can be extracted by hydrometallurgical process also.

CuCO3 . Cu(OH)2 + dil.H2SO4  CuSO4 + H2O + CO2
Fe
FeSO4 + Cu 
(VI) EXTRACTION OF LEAD

Lead does not occur in the free state. The important ores of lead are :
(i) Galena (PbS) (ii) Anglesite (PbSO4) and (iii) Cerussite (PbCO3).
Galena (PbS)
Froath
floatation
Roasting Self Refining

reduction
(i) Poling
(ii) Liquation
(iii) Parke's
(iv) Pattinson's
(v) Electrolytic refining
(V) EXTRACTION OF TIN
Main ore: Cassiterite or Tin stone SnO2
Tin Stone (SnO 2)
Magnetic
separation
Roasting Reduction Refining

by carbon
(i) Poling
(ii) Liquation
(iii) Electrolytic refining
(VI) EXTRACTION OF IRON
Ores : Haematite – Fe2O3 Limonite – 2Fe2O3 . 3H2O; Siderite FeCO3; Magnetite – Fe3O4,
Pyrite- FeS2.
Metallurgy
Process:
Haematite ore
Concentration Calcination followed

by Roasting
(Magnetic separator)
scrap iron ,carbon and air

Smelting + reduction steel
(blast furnace)
Wrought Iron
 Pig Iron : C  3.1 – 4.5%, small amounts of Si, S, P ; hard and brittle, obtained from blast furnace
 Wrought Iron : C  0.15 – 0.28%, purest form ; malleable, fibrous
 Steel : C  0.5 – 2% and other impuirites.
 Cast iron : C  2 – 5% and other impuirites.
Cast Iron
(Remolten form of Pig Iron)
Fast cooling Slow cooling
White cast iron

Grey cast iron
(having carbon impurity
(having carbon impurity
in the form of cementite)
in the form of graphite)
Manufacturing of wrought from cast iron :
Wrought iron is manufacturing from pudding furnace having inner lining of haematite (Fe2O3) which acts
as oxidant for impurities present in cast iron.
Manufacturing of steel from cast iron :

Process Flux O.A.
(i) Bassemerisation (Already discussed) CaO Hot air
(ii) Open - Hearth process (Siemen Martin’s process) CaO Hot O2
(iii) Electrical furnace process (Modern method) CaO O2 + energy from electrode
Mn  O.A.   MnO
Si  O.A. 
 SiO 2
S  O.A. 
 SO2 
P4 + O.A.  P2O5
MnO + SiO2  MnSiO3(slag)
P2O5 + Basic Flux  Phosphate Slag
Fe2O3
Cast iron   Wrougt iron  Spiegeleisen
   Steel
( oxidant ) alloy( Fe  Mn  C
)
(2% to 5% carbon (< 0.5 carbon (0.5 % to 2% carbon
and other impurity) and other impurity) andandotherimpurity)
Metallurgy
In modern age steel is manufactured by electrical furnace process or by L.D. (Linz - Donawitz)
process. In electrical furnace process heating effect is produced by passing electricity and all chemical
reactions are similar to open hearth process.
Heating Treatment of steel

(i) Annealing : Process of heating steel upto redness and then cooling it slowly is called annealing. In this
way steel becomes solft, malleable and elastic.
(ii) Quenching : Process of heating steel upto redness and then cooling it suddenly by plundging it into oil or
water is called quenching in this way steel become hard and brittle.
(iii) Tempering : Process of heating quenched steel much below redness and then colling it slowly is called
tempering in this way steel becomes neither so hard nor so brittle.
Surface Treatment of steel / Case- Hardening

(i) Carbdising : Process of forming hard coating of iron carbide over mild steel by heating it with charcoal
(ii) Nitriding : Process of forming hard coating of iron nitride by heating steel with ammonia gas
(iii) Cyaniding : Process of forming hard coating of iron cyanide by heating steel with K4[Fe(CN)6] gas
(VII) EXTRACTION OF ZINC

Occurrence :
Zinc is usually found in the combined state although traces of the metal in the native state have been
reported from Melbourne (Australia). Its chief ores are :
(i) Zinc blende or Sphalerite , ZnS.
(ii) Calamine , ZnCO3
(iii) Zincite, ZnO
(a) Extraction process : It involves the following steps :
Zinc Blende Froath floatation
Roasting Smelting
Zn Elelctrolytic refining
Impure Zn is purified by Electrolytic refining method or bydistillation.
(VIII) EXTRACTION OF ALUMINIUM

(a) Ores :
(i) Oxides : Bauxite Al2O3. 2H2O (chief) ; Diaspore Al2O3.H2O ; Corundum Al2O3.
(ii) Silicates : Felspar KAl Si3O8; Mica K2O. 3Al2O3. 6SiO2.2H2O; Kaolinite Al2O3. 2SiO2.2H2O
(iii) Fluorides : Cryolite Na3 Al F6
Metallurgy
(b) Process :
Bauxite Concentration by (i) Baeyer's process (Red Bauxite)

Al2O3 . 2H2O Leaching (ii) Hall's process (Red Bauxite)
(iii) Serpeck's process (White Bauxite)
Electrolytic
By Hall-Herault process
reduction
Refining by Hoop's process
(IX) MAGNESIUM : (Dow’s process)

Ores :
Carnallite MgCl2. KCl6H2O (main ore) : Epsom MgSO4.7H2O magnesite MgCO3.
Dolomite MgCO3.CaCO3 : (Mg is also found in Talc. asbestos and chlorophyll)
Sea water contains 0.13% magnesium as chloride and sulphate. It involves following steps.
(a) Precipitation of magnesium as magnesium hydroxide by slaked lime:
MgCl2 + Ca(OH)2  Mg(OH)2  + CaCl2 (ppt. reaction)
(b) Prepartion of hexahydrated magnesium chloride :

Mg(OH)2 + 2HCl(aq)  MgCl2 + 2H2O (Neutratlisation reaction)
The solution on concentration and crystallisation gives the crystals of MgCl2.6H2O.
(c) Preparation of anhydrous magnesium chloride :

MgCl2.6H2O    MgCl2 + 6H2O
Dry HCl ( g )
* It is not made anhydrous by simple heating because it gets hydrolysed.


MgCl2.6H2O   MgO + 5H2O + 2HCl
Metallurgy
EXERCISE-1
GENERAL PRINCIPLES INVOLVED IN METALLURGY / CONCENTRATION /
ORES AND THEIR CONCENTRATION
Q.1 Metallurgy is the process of
(A) Concentration of ore (B) Roasting of ore
(C) Extraction of metal from the ore (D) Adding carbon to the ore in blast furnace
Q.2 Which of the following metal is not found in free state

(A) Zn (B)Au (C) Ag (D) Hg
Q.3 All ores are minerals, while all minerals are not ores because
(A) The metal cannot be extracted economically from all the minerals
(B) Minerals are complex compounds
(C) The minerals are botained from mines
(D) All of these are correct
Q.4 Which one of the followng does not occur as sulphide ore
(A) Zn (B) Cr (C) Ag (D) Fe
Q.5 Electrometallurgical process is used to extract

(A) Fe (B) Pb (C) Na (D) Ag
Q.6 Which of the following metal is extracted by carbon reduction process

(A) Cu (B) Ca (C) Hg (D) Zn
Q.7 Which metal is extracted by electrolytic reduction method

(A) Cu (B) Ca (C) Fe (D)Ag
Q.8 Thermite process is used to extracted metals

(A) When their oxides can be reduced by carbon
(B) When their carbonates do not yield oxides by thermal decomposition
(C) When their sulphides cannot be converted into oxides by roasting
(D) When their oxides are highly stable
Q.9 'Lapis-Lazuli' is a blue coloured precious stone. It is mineral of the class

(A) Sodium-alumino silicate (B) Zinc cobaltate
(C) Basic copper carbonate (D) Prussian blue
Q.10 The lustre of a metal is due to

(A) its high density (B) polished surface
(C) its chemical inertness (D) presence of free electrons
Q.11 Which of the following processes is used in exctractive metaullurgyof magnesium?

(A) Fused salt electrolysis (B) Self reduction
(C)Aqueous solution electrolysis (D) Thermite reduction
Metallurgy
Q.12 Which metal is commercially extracted by hydrometallurgical process involving complexation?
(A) Mg (B)Au (C) Cu (D) Zn
Q.13 Which of the following metal is obtained by Self-Reduction process?

(A) Copper (B) Iron (C) Silver (D) Magnesium
Q.14 Cyanide process is used for the concentration of

(A)Au (B)Ag (C)Al (D) Both A & B
Q.15 Froth floatation process for the concentration of ores is an illustration of physical phenomenon of
(A)Adsorption (B)Absorption (C) Coagulation (D) Sedimentation
Q.16 The method of concentration of the ore that makes use of difference in densitybetween ore and impurities
is called
(A) Levigation (B) Leaching
(C) Magnetic separation (D) Liquation
Q.17 During concentration of Tin stone separation of sulframates of FeII and MnII is based on the fact
(A) SnO2 is paramagnetic (B) SnO2 is diamagnetic
(C) FeWO4 and MnWO4 are paramagnetic (D) Both B and C
Q.18 Leaching of Ag2S by NaCN solution is carried out in the presence of air it, because :
(A) [Ag(CN)2]¯ complex is formed in a reversible reaction
(B) oxidation of formed Na2S into Na2SO4 and sulphur
(C) both (A) and (B)
(D) none of the above
Q.19 In froth-floatation process, pine oil functions as

(A) activator (B) frother (C) collector (D) agitator
Q.20 Collector are the substance which combine with sulphide ore and make them water repellant, which of
the following substance can act as collector
(A) sodium ethyl xanthate (B) sodium xenate
(C) sodium pyrophosphate (D) adsorption
Q.21 Preferential wetting of ore by oil and gangue by water takes place during
(A) Levigation (B) Froth floatation (C) Leaching (D) Bessemerisation
Q.22 Concentration of sulphide ores can be carried out by

(A) Liquation (B) Leaching
(C) Froth-floatation process (D) Both B & C
Q.23 Froth floatation process for concentration of ores is an illustration of the practical application of:
(A)Adsorption (B)Absorption (C) Coagulation (D) Sedimentation
Q.24 The most abundant element in the earth crust is

(A)Aluminium (B) Oxygen (C) Silicon (D) Iron
Metallurgy
Q.25 Titanium containing ore found in the earth crust is
(A) Bauxite (B) Dolomite (C) Chalcopyrites (D) Ilmenite
Q.26 Silicon is main constituent of

(A)Alloys (B) Rocks (C) Seawater (D) Plants
Q.27 A mineral is called ore if

(A) Metal present in mineral is precious (B) Metal present in mineral is in low content
(C) Metal present in mineral is in rich content (D) Metal cannot be extracted from it
Q.28 Which of the following does not contain Mg

(A) Magnetite (B) Asbestos (C) Magnesite (D) Carnallite
Q.29 Composition of azurite mineral is

(A) CuCO3CuO (B) Cu(HCO3)2.Cu(OH)2
(C) 2CuCO3.Cu(OH)2 (D) CuCO3.2Cu(OH)2
Q.30 The salt which is least likely to be found in minerals is

(A) Halides (B) Carbonate (C) Sulphide (D) Nitrate
Q.31 Metal which can be extracted from all the three dolomite, magnesite and carnallite is
(A)Na (B) K (C) Mg (D) Ca
Q.32 Cinnabar is an ore of

(A) Hg (B) Cu (C) Pb (D) Zn
Q.33 An example of halide ore is

(A) Galena (B) Bauxite (C) Cinnabar (D) Cryolite
Q.34 Which of the following is not an ore

(A) Bauxite (B) Malachite (C) Zinc blende (D) Pig iron
Q.35 Which of the following ore is used for industrial extraction of aluminium
(A) Corundum (B) Kaolin (C) Cryolite (D) Bauxite
Q.36 Siderite is an ore of

(A) Cu (B)Al (C) Ag (D) Fe
Q.37 Corundum is
(A)Al2O3.H2O (B) Al2O3 (C) Al2O3.2H2O (D) Al2O3.2SiO2.2H2O
Q.38 Formula of magnetite is

(A) Fe2O3 (B) Fe2O3.3H2O (C)FeCO3 (D) Fe3O4
Q.39 Which of the following ores does not represent the ore of iron
(A) Haematite (B) Magnetite (C) Cassiterite (D) Limonite
Metallurgy
Q.40 Which of the following ore is called malachite
(A) CuFeS2 (B) CuCO3.Cu(OH)2
(C) Cu2S (D) 2CuCO3.Cu(OH)2
Q.41 Calamine is
(A)ZnSO4 (B) ZnO (C) ZnS (D) ZnCO3
Q.42 Which of the following statement is incorrect·

(A) Silver glance mainly contains silver sulphide (B) Gold is found in native state
(C) Tin stone is oxide ore (D) Chalcocite: CuFeS2
Q.43 Which ore contains both iron and copper?

(A) Cuprite (B) Chalcocite (C) Chalcopyrite (D) Malachite
Q.44 Commercially important ore of lead from which it is extracted is
(A)Anglesite (B) Cerussite (C) Galena (D) Siderite
Q.45 Cassiterite is an ore of

(A) Mn (B) Ni (C) Sb (D) Sn
Q.46 Among the following statements, the incorrect one is

(A) Calamine and siderite are carbonates (B)Argentite and cuprite are oxides
(C) Zinc blende and pyrites are sulphides (D) Hornsilver is halide ore
Q.47 Which of the following sulphide ore is concentrated by leaching

(A)Argentite (B) Galena (C) Copper pyrite (D) Sphalerite
Q.48 Froth floatation process is used for the concentration of

(A) Oxide ores (B) Sulphide ores (C) Halide ores (D) Sulphate ores
Q.49 Process used for the concentration of ore is

(A) Froth floatation (B) Roasting (C) Electrolysis (D) Bessemerization
Q.50 Magnetic separation is used for the concentration of

(A) Horn silver (B) Gypsom (C) Chromite (D) Magnesite
Q.51 Cassiterite is concentrated by
(A) Levigation (B) Electromagnetic separation
(C) Froth floatation (D) Liquation
Q.52 Bauxite ore is concentrated by

(A) Froth floatation (B) Cyanidation
(C) Chemical leaching (D) Calcination
Q.53 Zinc blende is concentrated by
(A) Froth floatation (B) Magnetic separation
(C) Leaching (D) Roasting
Q.54 Gravity separation process is primarily used for the concentration of

(A) Calamine (B) Haematite (C) Chalcopyrite (D) Bauxite
Metallurgy
Q.55 Froth floatation process is used for concentration of
(A) Chalcopyrite (B) Bauxite (C) Haematite (D) Calamine
Q.56 Which one of the following beneficiation process is used for the ore,Al2O3.2H2O
(A) Froth floatation (B) Leaching (C) Liquation (D) Magnetic separation
Q.57 Naturall occuring materials from which an element can be extracted economically are called
(A) Ores (B) Minerals (C) gangue (D) None ofthese
Q.58 Cassiterite is concentrated by

(A) Levigation (B) Electromagnetic separation
(C) Floatation (D) Liquefaction
Q.59 Wolframites are separated from tin stone ore by the process of
(A) Calcination (B) Electromagnetic process
(C) Roasting (D) Smelting
Q.60 Which of the following is not an ore?

(A)Azurite (B) Siderite (C) Clay (D) Cerussite
Q.61 Select the correct match:

Column-I (Method of conc.) Column-II (Ores)
X Magnetic separation (a) Ag2S
Y froth floation (b) FeCr2O4
Z Leaching (c) Al2O3.2H2O
X Y Z X Y Z
(A) (a) (b) (c) (B) (b) (a) (c)
(C) (c) (a) (b) (D) (b) (c) (a)
Q.62 Incorrect statement is

(A) Casseterite, chromite and haematite can be concentrated by hydraulic washing method.
(B) In Hall's process Red Bauxite is purified by leaching,
(C) Sulphide ore is concentrated by froth floatation process.
(D) During roasting of sulphide ore both metal oxide and metal sulphate are formed.
Q.63 Which one of the following is not a method of concentration of ore?

(A) Gravity separation (B) Froth floatation process
(C) Electromagnetic separation (D) Bessemerization
Q.64 Leaching is commercially used in the concentration of:

(A) Haematite (B)Argentite (C) Galena (D) Cinnabar
Q.65 In the froth floatation process, NaCN is added as depressant when galena is associated with impurity of
ZnS, because
(A) Pb(CN)2 is precipitated while ZnS remains unaffected,
(B) ZnS forms soluble complex Na2[Zn(CN)4] while PbS combines with frother.
(C) PbS forms soluble complex Na2[Pb(CN)4] while ZnS combines with frother.
(D) NaCN regenerates ZnS from complex [Zn(CN)4]2–.
Metallurgy
Q.66 Which mineral has been named incorrectly?
(A) bauxite : Al2O3.2H2O (B) Chalcocite : Cu2S
(C) Cryolite : 3NaF. AlF3 (D) Feldspar : Be3Al2Si6O18
Q.67 Carnallite does not contain

(A) K (B) Ca (C) Mg (D) Cl
Q.68 Identify the metal M which is present in its ore as MFeS2 :

(A) copper (B) tin (C) lead (D) zinc
Q.69 The main ore of copper is:

(A) chalcocite (B) Chalcopyrite (C)Azurite (D) Cerussite
Q.70 Three most abundunt elements in the earth crust in their decreasing order of percentage.
(A) O, Si, Al (B) Si, O, Al (C) Al, O, Si (D) O, Fe, Si
Q.71 An ore containing the impurity of FeCr2O4 is concentrated by

(A) magnetic-separation (B) gravity separation
(C) froth-floatation method (D) electrostatic method
Q.72 Formula of dolomite is :

(A) CaMg(CO3)2 (B) MgCO3 (C) CacO3.MgCO3 (D) (A) & (C) both
Q.73 Incorrect statement is :

(A) calamine and siderite are carbonates (B) argentite and cuprite are oxide
(C) zinc blende and pyrites are sulphides (D) malachite and azurite are ores of copper
Q.74 The impurities present in a mineral are called:

(A) gangue (B) f1ux (C) pulverization (D) nuggets
Q.75 Correct statement is:

(A) Magnetite is an ore of magnesium (B) Pyrolusite is mixed oxide of Mn
(C) Siderite is carbonate ore of iron (D) FeS2 is rolled gold
Q.76 Elements found in native state are

(A) Mg & Al (B) Cu & Fe (C) Zn & Pb (D) Pt & Au
Q.77 The reason, for floating of ore particles in concentration by froth floatation process is that:
(A) they are light (B) they are insoluble
(C) they are charged (D) they are adsorbed over air bubbles
Q.78 The formula of carnallite is :

. (A) LiAl(Si2O5)2 (B) KCl.MgCl2.6H2O
(C) K2OAl2O3.6SiO2 (D) KCl.MgCl2.2H2O
Q.79 Which of the following is not an ore of iron?

(A) Haematite (B) Limonite (C) Siderite (D) Malachite
Metallurgy
Q.80 "Fool's gold" is
(A) iron pyrites (B) horn silver (C) copper pyrites (D) bronze
REDUCTION / EXTRACTION OF METALS

Q.81 Extraction of zinc from zinc blende is achieved by
(A) Electrolytic reduction
(B) Roasting followed by reduction with carbon
(C) Roasting following reduction with another metal
(D) Roasting followed by self-reduction
Q.82 Roasting is generally done in case of the following.

(A) Sulphate ores (B) Silicate ores (C) Sulphide ores (D) Carbonate ores
Q.83 Electric furnaces are lined with magnesia because

(A) it is not affected by acids (B) it gives oxygen on heating
(C) it melts at very high temperature (D) it has no effect of electricity
Q.84 Purpose of smelting of an ore is

(A) To oxidise it (B) To reduce it
(C) To remove vaporisable impurities (D) To obtain an alloy
Q.85 The role of calcination in metaullurgical operation is

(A) To remove moisture (B) To decompose carbonates
(C) To decompose organic matter (D) To achieve all the above
Q.86 The metallurgical process in which metal is obtained in fused state from its ore is called
(A) Smelting (B) Roasting (C) Calcination (D) Froth floatation
Q.87 Which of the following processes involves smelting

(A) ZnCO3  ZnO + CO2 (B) Fe2O2 + 3 CO  2Fe + 3CO2
(C) 2PbS + 3O2  2 PbO + 2SO2 (D) Al2O3·2H2O  Al2O3 + 2H2O
Q.88 Which of the following ore is subjected to roasting during metallurgical operations for getting the metal
oxide
(A)Argentite (B) Zinc blende (C) Malachite (D) Limonite
Q.89 Flux is added to remove

(A)Acidic impurities (B) Basic impurities
(C)All impurities of ores (D) Both (A) and (B)
Q.90 Which element is used as a reducing agent in smelting

(A) C (B)Al (C) Zn (D) None of these
Q.91 According to Ellingham diagram, the oxidation reaction of carbon to carbon monoxide may be used to
reduce which one of the following oxides at the lowest temperature
(A) Al2O3 (B) Cu2O (C) MgO (D) ZnO
Metallurgy
Q.92 In blast furnace, maximum temperature is in
(A) Zone of fusion (B) Zone of combustion
(C) Zone of slag formation (D) Zone of reduction
Q.93 During smelting, an additional substance is added which combines with impurities to form a fusible
product. It is known as
(A) slag (B) mud (C) gangue (D)flux
Q.94 Which one of the following reaction is an example of calcination process?

(A) 2Ag + 2HCl + [O]  2AgCl + H2O
(B) 2Zn + O2  2 ZnO
(C) 2 ZnS + 3O2  2 ZnO + 2SO2

(D) 2 PbCO3·Pb(OH)2  3PbO + CO2 + H2O
Q.95 Which of the following metal is obtained by electrolytic reduction process ?

(A) Fe (B) Cu (C) Ag (D) Mg
Q.96 Heating of ore in the absence of air below its melting point is called
(A) Leaching (B) Roasting (C) Smelting (D) Calcination
Q.97 Which of the following flux is used to remove acidic impurities in metallurgical process?
(A) Silica (B) Lime stone (C) Borax (D) Sodium
Q.98 The process of converting hydrated alumina into anhydrous alumina is called
(A) Roasting (B) Smelting (C) Dressing (D) Calcination
Q.99 Which of the following statements about the advantage of roasting of sulphide ore before smelting is not
true?
(A) fGº of the sulphide is more negative than that of CS2
(B) fGº is negative for roasting of sulphide ore to oxide
(C) fG of carbon reduction of metal oxide to free metal is more negative at higher temperature
(D) Carbon and hydrogen are suitable reducing agents for metal sulphides
Q.100 The value of fGº for Cr2O3 is – 540 kJ mol–1 and that of Al2O3 is – 827 kJ mol–1. Is the reduction of
Cr2O3 byAl is feasible reaction
(A) The data is incomplete (B) The reaction is feasible
(C) The reaction is not feasible (D) The reaction may or may not be feasible
Q.101 Heating pyrites in air for oxidation of sulphur is called

(A) Slagging (B) Smelting (C) Roasting (D) None of these
Q.102 Which of the following condition is incorrect for metal oxide formation from metal and oxygen at given
temp.
(A) H = – ve (B) S = – ve (C) S = + ve (D) None of these
Q.103 Calcination is not carried out for

(A) Calalmine (B) Malachite (C) Chalcopyrite (D) Dolomite
Metallurgy
Q.104 Consider the following statements :
Roasting is carried out to :
(i) convert sulphide ore to metal oxide and metal sulphate
(ii) remove water of hydration
(iii) organic matter is decomposed into volatile substance
(iv) remove arsenic and sulphuric impurities as their oxides
Of these statements :
(A) (i), (ii) and (iii) are correct (B) Only (i) and (iv) are correct
(C) (i), (ii) and (iv) are correct (D) All are correct
Q.105 Identify the metal M whose extraction is based on the following reactions :
MS + 2O2  MSO4 ; 2 MS + 3O2  2MO + 2SO2
MS + 2 MO 3M + SO2 ; MS + MSO4  2M + 2SO2
(A) Magnesium (B)Aluminium (C) Lead (D) Tin
Q.106 Which of the following metal is not extracted commercially by carbon reduction process?
(A) Zn (B) Fe (C) Hg (D) Sn
Q.107 Which of the following reaction does not represent to calcination.

(A) Al(OH)3  Al2O3 
(B) ZnS + O2  ZnSO4


(C) CuCO3.Cu(OH)2  CuO + CO2 + H2O (D) MgCl2.6H2O Dry MgCl2
HCl
Q.108 An ore after levigation is found to have acidic impurities . Which of the following can be used as flux
during smelting operation?
(A) Na2B4O7 (B) CaCO3 (C) SiO2 (D) Na3PO4
Q.109 Which of the following reactions represent(s) the self-reduction process?
HgS  O 2  HgO  SO 2 Cu 2S  O 2  Cu 2 O  SO 2

(A)  (B) 
HgO  HgS  Hg  SO 2 Cu 2S  Cu 2O  Cu  SO 2
PbS  O 2  PbO  SO 2
(C)  (D)All of these
PbO  PbS  Pb  SO 2
Q.110 Which of the following represents thermite reduction?


(A) 3Mn3O4 + 8Al  9Mn + 4Al2O3 (B) Al2O3 + 3Mg  2Al + 3MgO
(C) Cu2S + 2Cu2O  6Cu + SO2 (D) Fe2O3 + 3CO  2Fe + 3CO2
Q.111 Choose the correct option for the following statements
Statement-1 Sulphide ore is firstly converted to oxide and then it is subjected to reduction for the
extraction of metal.
Statement-2 In calcination, the ore is heated in a regular supply of air in a furnace at a temperature
below melting point of the calcined product.
Statement-3 Carbon can be used in place of Mg metal during commercial extraction of Ti-metal in
Kroll process.
Statement-4 In commercial extraction of Mn by Thermite process, three parts of MnO2 and one part
of Al as reductant, is used.
(A) TTFF (B) FFFT (C) TFFT (D) TFFF
Metallurgy
Q.112 Extraction of manganese from Mn3O4 by the use of aluminium is an example of :
(A)Amalgamation (B) hydrometallurgy (C) electrometallurgy (D) Pyrometallurgy
Q.113 Slag is formed by reaction between:

(A) impurities and coke (B) impurities and ore
(C) impurities and flux (D) flux and coke
Q.114 The slag consists of molten impurities, generally, in the form of:
(A) Metal carbonate (B) Metal silicate
(C) Metal oxide (D) Metal nitrate
Q.115 Refractory materials are used in furnaces because

(A) they maintain temperature of the furnace (B) they can withstand high temperature
(C) they prevent formation of CO (D) they help in burning of coal
Q.116 Which of the following statement is correct regarding the slag obtained during the extraction of a metal
like copper or iron?
(A) The slag is lighter and has lower melting point than the metal
(B) The slag is heavier and has lower melting point than the metal
(C) The slag is lighter and has higher melting point than the metal
(D) The slag is heavier and has higher melting point than the metal
Q.117 Among the following groups of oxides, the group containing oxides that is reduced by carbon for their
respective extraction.
(A) CaO and K2O (B) Fe2O3, ZnO and SnO2
(C) Al2O3, B2O3 (D) Cr2O3, Mn3O4
Q.118 Which of the following match is incorrect

Extraction Method Metal(s)
(A) Self reduction Hg, Pb
(B) Electrolytic reduction Na, Al
(C) Hydrometallurgy Pb, Zn
(D)Alumino-thermite reduction Mn, Cr
Q.119 Heating of pyrites in air for oxidation of sulphur is called

(A) Roasting (B) Calcination (C) Smelting (D) Levigation
Q.120 Which is not basic flux

(A) Lime stone (B) SiO2 (C) Magnesite (D) None
Q.121 In the extraction of iron lime stone added to the blast furnace, calcium ion is obtained mainly in the form
of
(A) CaSiO3 (B) CaCO3 (C) Ca (D) CaO
Q.122 The slag obtained during the extraction of copper from copper pyrites is composed mainly of
(A) CaSiO3 (B) FeSiO3 (C) CuSiO3 (D) SiO2
Metallurgy
Q.123 Which of the following reaction taking place in the Blast furnace is endothermic
(A) CaCO3  CaO + CO2 (B) 2C+ O2  2CO
(C) C + O2  CO2 (D) Fe2O3 + 3CO  2Fe + 3CO2
Q.124 In the modern blast furnaces, in the extraction of iron the charge consists of a mixture of
(A) Fe2O3+ lime stone + anthracite coal (B) Fe2O3+ limestone + coke
(C) Fe2O3.3H2O + dolomite + coke (D) Iron pyrites + lime stone + bituminous coal
Q.125 A metal obtained directly by roasting of its sulphide ore is

(A) Cu (B) Pb (C) Hg (D) Zn
Q.126 Heating mixture of Cu2O and Cu2S will give

(A) Cu + SO2 (B) Cu + SO3 (C) CuO +CuS (D) Cu2O + S
Q.127 In the extraction of copper from its sulphide ore, the metal is finally obtained by the reduction of cuprous
oxide with
(A) Copper (I) sulphide (Cu2S) (B) Sulphur dioxide (SO2)
(C) Iron sulphide (FeS) (D) Carbon monoxide (CO)
Q.128 Alumino-thermite process is used for the extraction of

(A)Al (B) Cr (C) Fe (D) Cu
Q.129 In alumino-thermite process, aluminium is used as

(A) Oxidising agent (B) Flux
(C) Reducing agent (D) Ignition agent
Q.130 Aluminium is extracted in large quantities by

(A) Heating cryolite in a limited quantity of air
(B) Reducing aluminium oxide with coke
(C) Reducing aluminium oxide with sodium
(D) Electrolysingaluminium oxide dissolved in fused cryolite
Q.131 After partial roasting, the sulphide of lead is reduced by

(A) Reduction by carbon (B) Electrolysis
(C) Self-reduction (D) Cyanide process
Q.132 Aluminium is extracted from alumina (Al2O3) byelectrolysis of a molten mixture of

(A) Al2O3 + HF + NaAlF4 (B) Al2O3 + CaF2 + NaAlF4
(C) Al2O3 + Na3AlF6 + CaF2 (D) Al2O3 + KF + Na3AlF6
Q.133 Extraction ofchromium from chromic oxide, the method used is

(A)Alumino-thermic process (B) Electrolytic reduction
(C) Carbon reduction (D) Carbon monoxide reduction
Q.134 Bauxte ore is made up ofAl2O3 + SiO2 + TiO2 + Fe2O3. The ore is treated with conc. NaOH solution
at 500 K and 35 bar pressure for few hours and filtered, In the filtrate the species present, are
(A) NaAlO2 only (B) Na2Ti(OH)6 only
(C) Both NaAlO2 and Na2SiO3 (D) Na2SiO3 only
Metallurgy
Q.135 The autoreduction process is not used for extraction of
(A) Hg (B) Cu (C) Pb (D) Fe
Q.136 Pb and Sn are extracted from their chief ore respectively by.
(A) Carbon reduction and self reduction (B) Self reduction and carbon reduction.
(C) Electrolysis and self reduction. (D) Self reduction and electrolysis.
Q.137 Slag formed during extraction of iron is

(A) Fe3C (B) FeSiO3 (C) MgSiO3 (D) CaSiO3
Q.138 The methods chiefly used for the extraction of lead and tin from their ores are respectively.
(A) Self reduction and carbon reduction (B) Self reduction and electrolytic reduction
(C) Carbon reduction and self reduction (D) Cyanide process and carbon reduction
Q.139 Complex is formed in the extraction of

(A) Fe (B) Cu (C) Ag (D) Na
Q.140 Spiegelesin is an alloy of

(A) Fe, Co and Cr (B) Fe, Co and Mg (C) Fe, Mg and C (D) Fe, C and Mn
Q.141 From which of the following ore, the concerned metal is not commercially extracted by self reduction.
(A) Ag2S (B) PbS (C) CuFeS2 (D) Cu2S
Q.142 The reduction of a metal oxide byaluminium is called:

(A) Ellingham process (B) Goldschmidt's aluminothermite process
(C) Kroll's process (D) VanArkel process
Q.143 Blister Cu contains about:

(A) 60 % Cu (B) 90 % Cu (C) 98 % Cu (D) 100 % Cu
Q.144 Self-reduction of Cu2S to Cu is carried out in ............ step

(A) Roasting (B) Smelting (C) Bessemerization (D) Poling
Q.145 In which of the following process, silver metal can not be obtained.
(A)As a by product in the electrolytic refining of copper
(B) Parke's process
(C) By reaction of argentite ore with excess KCN followed by metal displacement
(D) By treatment of Horn silver withAqua Regia
Q.146 Incorrect reduction process is :

(A) 2[Ag(CN)2]¯ + Zn  [Zn(CN)4]2–+'2Ag

(B) Cu2O + H2  2Cu + H2O

(C) ZnO + Cu  Zn + CuO

(D) TiCl4+ 2Mg  Ti + 2MgCl2
Metallurgy
Q.147 In which of the following isolations no reducing agent is required:
(A) Iron from haematite (B) Tin from Tinstoe
(C) Mercury from cinnabar (D) Zinc from zinc blende
Q.148 Which of the following combination of reactions is involved during commercial extraction of copper
metal
3  
(A) Cu2S + O  Cu2O + SO2 ; Cu2O + C  Cu + CO
2 2
3  
(B) Cu2S + O  Cu2O + SO2 ; 2Cu2O + Cu2S  6Cu + SO2
2 2
3  
(C) Cu2S + O  Cu2O + SO2 ; 2Cu2O + Si  4Cu + SiO2
2 2
3  
(D) Cu2S + O2  Cu2O + SO2 ; Cu2O + CO  2Cu + CO2
2
Q.149 Iron obtained directlyfrom blast furance is:
(A) wrought iron (B) cast iron (C) pig iron (D) steel
Q.150 Which one of the following reactions will occur on heatingAgNO3?

(A) 2AgNO3  2Ag + N2 + 3O2 (B) 3AgNO3  Ag2O + N2O3 + O2
(C) 2AgNO3  2AgNO2 + O2 (D) 2AgNO3 2Ag + NO2 + O2
Q.151 Boron can be obtained by various methods but not by:

(A) thermal decomposition of B2H6 (B) pyrolysis of BI3 (VanArkel)
(C) Reduction of BCl3 by H2 (D) electrolysis of fused BCl3
Q.152 Black tin is

(A) an alloy of Sn (B) an allotrope of Sn
(C) 60-70 percent SnO2 (D) 100 percent SnO2
Q.153 Incorrect statement during extraction ofAl by Hall-Heroult process is :

(A) cryolite Na3[AlF6] lowers the working temperature.
(B) Al is obtained at cathode and probably CO at anode
(C) Anode rods are disintegrated due to their oxidation
(D) Pure aluminium floats above molten electrolyte.
Q.154 Which of the following species is desirable substance in extraction of copper but not in extraction of
iron?
(A) CaSiO3 (B) FeSiO3 (C) SiO2 (D) coke
Q.155 Main source of lead is PbS. It is converted to Pb by:

(A) : PbS air

PbO + SO 2 (B) : PbS air

PbO + PbS
c
Pb + CO2 Pb + SO2
Self-reduction pocess is:
(A)A (B) B (C) both (D) none
Metallurgy
Q.156 Which of the following reaction does not occur in Bessemer's converter?
(A) FeS + Cu2O  Cu2S + FeO (B) 2Cu2S + 3O2  2Cu2O + 2SO2
(C) 2CuFeS2+ O2  Cu2S + 2FeS + SO2 (D) FeO + SiO2  FeSiO3
Q.157 In McArthur forest method zinc powder is used as

(A) oxidising agent (B) reducing agent (C) solvent (D) solvating agent
Q.158 The metal which can be extracted by both sea-water and ores from the earth's crust is:
(A) Magnesium (B) Lead (C) Iron (D)Aluminium
Q.159 Electrolyte used in the commercial extraction of aluminium is :

(A)Al(OH)3 in NaOH solution
(B) Molten mica and CaF2
(C) Molten mixture of Al2O3, Na3AlF6 & CaF2
(D) Molten potash alum
Q.160 Use T if statement is true and F if it is false for following statement.

(i) Cu metal is extracted from its sulphide ore by reduction of Cu2O with FeS.
(ii) Calamine containing impurity of FeCr2O4 is concentrated by magnetic separation.
(iii) Self reduction is used for the extraction of Cu & Hg.
(iv) Cassiterite and Rutile are oxide ores of their respective metals
(A) TFTT (B) TIFT (C) FTTT (D) FFFT
Q.161 During extraction of aluminium the carbon anodes are replaced periodically because:
(A) carbon anodes are gradually lost due to formation ofAl4C3
(B) Carbon anodes melt and mix up with the electrolyte
(C) Oxygen liberated at the carbon anode reacts with anode to form CO
(D) Carbon anode reduces Al2O3 into Al
Q.162 In the extraction of aluminium

Process X : Used for purification of red bauxite by leaching.
Process Y : Used for purification of white bauxite and removes impurity of Z then correct statement is.
(A) X = Hall and Heroult's process and Z = SiO2
(B) X =Baeyer's process and Z = SiO2
(C) X =Serpeck's process and Z = iron oxide
(D) X =Baeyer's process and Z = iron oxide
Q.163 Magnesium is commerciallyextracted by :

(A) self-reduction process (B) Dow's sea process
(C) Thermite reduction (D) Leaching followed by metal displacement
Q.164 Bauxite is leached with:

(A) N2 + Coke (B) NaCN (C) NaOH (D) Na2CO3
Q.165 Silver ore dissolves in dilute solution of NaCN in the presence of air to form:
(A)AgCN (B) [Ag(CN)2]¯ (C) AgSCN (D) [Ag(CN)4¯]
Metallurgy
Q.166 For extraction of sodium from NaCl, the electrolytic mixture NaCl + KCl + CaCl2 is used. During
extraction process, only sodium is deposited on cathode but K and Ca do not because
(A) Na is more volatite than K and Ca
(B) Na is less reactive than K and Ca
(C) NaCl is less stable than Na3AlF6 and CaCl2
(D) the discharge potential of Na+ is less than that of K+ and Ca2+ ions.
Q.167 What is the chemical composition of matte?

(A) Cu2O + FeS (B) Cu2O + Cu2S (C) FeS + SiO2 (D) Cu2S + FeS
Q.168 Dow's process is used for:

(A) Extraction of sodium metal (B) Extraction of Mg from molten carnallite
(C) Extraction of magnesium from sea water (D) Purificationof aluminium
Q.169 Which of the following reaction occurs in the reduction zone during extraction of iron?
(A) CaO + SiO2 CaSiO3(slag) (B) Fe2O3 + 3C  2Fe + CO
(C) FeO + CO  Fe + CO2 (D) CO2+ C  2CO
Q.170 In the metallurgy of iron, the upper layer obtained at the bottom of blast furnace mainly contains:
(A) CaSiO3 (B) Spongy iron (C) Fe2O3 (D) FeSiO3
Q.171 In the extraction of aluminium during electrolysis stage:

(A)Al2O3 undergoes dissociation
(B)AlF3 undergoes dissociation
(C)Al2O3 andAlF3 both underg'o dissociation
(D) Neither of the two undergoes dissociation
Q.172 In the extraction of copper from its sulphide ore the metal is formed by the reduction of Cu2O with:
(A) FeS (B) CO (C) Cu2S (D) SO2
Q.173 Which one of the following statements is incorrect?

(A) Tin is extracted by carbon reduction (smelting)
(B)Aluminium is extracted by Hall's process which involves carbon reduction.
(C) Extraction of lead does not involve bessemerisation
(D) Silver is extracted by cyanide process
Q.174 Fused carnallite on electrolysis gives:

(A) Ca and Cl2 (B) Na and CO2 (C) Al and Cl2 (D) Mg and Cl2
REFINING
Q.175 VanArkel method of purification of metals involves converting the metal to a
(A) Volatile stable compound
(B) Volatile thermally unstable compound
(C) Non volatile stable compound
(D) None of the above
Metallurgy
Q.176 If the impurityin a metal has a greater affinityfor oxygen and is more easily oxidised than the metal, then
the purification of metal may be carried out by
(A) Cyanidation (B) Zone refining (C) Electrolytc refining (D) Cupelation
Q.177 (Ag + Pb) alloy Melt Upper Layer ( X )

   (Ag + Pb + Zn) melt Cool
and zinc is added
     Select
Bottom Layer ( Y )
correct statement based on above scheme
(A) Layer X contain Zn and Ag
(B) Layer Y contains Pb andAg but amount of silver in this layer is smaller than in layer X
(C) X and Y are immiscible layer
(D)All are correct statements
Q.178 The method of zone refining is based on the principle of

(A) Greater solubilityof the impurity in the molten state than in the solid
(B) Greater mobility of the pure metal than that of the impurity
(C) Higher melting point of the impurity than that of the pure metal
(D) Greater noble character of the solid metal than that of the impurity
Q.179 Van-Arkel method of purification of metals involves converting the metal to a

(A) Volatile thermally stable compound (B) Non-volatile stable compound
(C) Volatile thermally unstable compound (D) None of the above
Q.180 Zone refining is based on the principle of

(A) fractional distillation (B) fracitonal crystallisation
(C) partitition coefficient (D) chromatographic separation
Q.181 In electrorefining of metals , the anode is made of :

(A) Impure metal concerned (B) Pure metal concerned
(C) Graphite (D) Platinum
Q.182 Which of the following statement is incorrect?

(A) Liquation is applied when the metal has low melting point than those of impurities.
(B) Presence of carbon in steel makes it hard due to having cementite impurity.
(C) Less reactive metals like Hg, Pb and Cu are obtained by auto reduction from their sulphide ores.
(D)Amalgamation is used for purification of mercury
Q.183 Zinc does not form alloy with
(A) Cu (B) Sn (C)Pb (D)Ag
Q.184 Which ofthe followingprocess involves the principle of fractional crystallisation for refiningof an element?
(A) Parke's process (B) Mond's process (C) Van Arkel process (D) Zone refining
Q.185 Mg can be obtained by:
(A) heating MgCl2(anhydrous) with Na in the atmosphere of coal gas
(B) electrolysis of fused anhydrous carnallite
(C) both methods
(D) one of.the above.
Metallurgy
Q.186 NaCl and CaCl2 are added to fused MgCl2 during extraction of Mg because.
(A) Melting point of electrolyte is decreased and its conductivity is increased
(B) Melting point of electrolyte is increased and its conductivity is decreased
(C) Both melting point and conductivity of electrolyte are decreased
(D) Both melting point and conductivity of electrolyte are increased
Q.187 Incorrect match is
(A) Bayer's method NaOH solution
(B) Matte 98% CuS + 2% FeS
(C) VanArkel method BI3
(D) Thomas slag Bessemerization
Q.188 Purest form of iron is :
(A) cast iron (B) wrought iron (C) pig iron (D) None ofthese
Q.189 Tempering of steel:
(A) to obtain steel of a particular hardness
(B) increases mechanical strength
(C) changes content of carbon in the form of cementite
(D)All of the above
Q.190 Bessemerisation is used in the extraction / Refining of
I : Fe II : Cu III : Al IV: Silver
(A) I, II (B) II, III (C) I, III (D) all
Q.191 The method of extraction ofAg by cyano complex formation followed by metal displacement is called:
(A) Parke's method (B) McArthur-Forest method
(C) Serpeck method (D) Hall's method
Q.192 Silica is added during extraction of copper in order to remove
(A) cuprous sulphide (B) ferrous oxide
(C) cupric oxide (D) cuprous oxide
Q.193 Addition of manganese makes steel useful in making rails of railroads, because manganese
(A) gives hardness to steel (B) helps the formation of oxides of iron
(C) reduces impurity of SiO2 into silicon (D) reduces hardness
Q.194 Apiece of steel is heated to red hot and then it is dipped into cold water, this treatment of iron makes it
(A) soft and malleable (B) hard but not brittle
(C) more brittle (D) hard and brittle
Q.195 Modern method of steel manufacturing is

(A) open hearth process (B) L.D. Process
(C) Bessemerisation (D) Cupellation
Q.196 The chemical process of manufacturing of steel from its ore haematite involves
(A) oxidation (B) reduction followed by oxidation
(C) oxidation followed by reduction (D) oxidation followed bydecomposition and reduction
Q.197 Which of the following metal acts as scavenger in steal manufacturing.

(A) Cr (B) Mn (C) Ti (D) Pb
Metallurgy
Q.198 Railway wagon axles are made by

(A) Sherardising (B)Annealing (C) Tempering (D) Case hardening
Q.199 In electrolytic refining of metals, electrolysis of an aqueous solution of its complex salt is done with
impure metal as anode and an strip of pure metal as cathode. This method cannot be used for the refining
of the metal
(A) Silver (B) Copper (C)Aluminium (D) Zinc
Q.200 Cupellation process is used in the metallugry of

(A) Copper (B) Silver (C)Aluminium (D) Iron
Q.201 Zone refining is a method to obtain

(A) Ultra pure Hg (B) Ultra pure Lead (C) Ultra pure Silicon (D) Ultra pure Sn
Q.202 Metal which is refined by poling is

(A) Sodium (B) Blister copper (C) Zinc (D) Silver
Q.203 Silver obtained from argentiferrous lead containing lead impurityis purified by
(A) Distillation (B) Froth floatation
(C) Cupellation (D) Aqueous NaCN in absence of air
Q.204 The method not used in metallurgy to refine the impure metal is
(A) Mond's process (B) Van-Arkel process (C) Froth floatation (D) Liq uation
Q.205 Method used for obtaining ultra pure silicon used as a semiconductor material is
(A) Oxidation (B) Electrochemical (C) Crystallization (D) Zone refining
Q.206 In electrorefining of copper, some gold is deposited as

(A) anode mud (B) cathode mud (C) flux (D) slag
Q.207 Which method of purification is represented bythe following equation?

Ti(s) + 2I2 (g) 523
 K
 TiI4 (g) 1700
 K
 Ti(s) + 2I2 (g)
(A) Zone refining (B) Cupellation (C) Poling (D) Van-Arkel
Q.208 Refining of silver is carried out by :

(A) Liquation (B) Poling (C) Cupellation (D) Vapour phase refining
Q.209 Which does not represent correct method?


(A) TiCl4 + 2 Mg  Ti + 2MgCl2 : Kroll process

(B) Ni(CO)4  Ni + 4CO : Mond's process

(C) PbI2  Pb + I2 : Van Arkel process

(D) ZrI4  Zr + 2I2 : Van Arkel process
Q.210 In the form of by product, tungstan is mainly obtained during electrolysis refining of :
(A) Pb (B) Sn (C) Cu (D)Al
Metallurgy
Q.211 In the extraction of nickel by Mond's process, the metal is obtained by:
(A) electrochemical reduction (B) thermal decomposition
(C) chemical reduction byaluminium (D) reduction by carbon
Q.212 When copper is purified by electrorefining process, noble metals likeAg andAu are found in
(A) cathode mud (B) over anode
(C) anode mud (D) over cathode or anode
Q.213 Formation of Ni(CO)4 and subsequent its decomposition into Ni and CO (recycled) makes basis of
Mond's process
T1 T2
Ni + 4CO  Ni(CO)4  Ni + 4CO
T1 and T2 are:
(A) 100°C, 50°C (B) 50°C, 100°C (C) 50°C, 230°C (D) 230°C, 50°C
Q.214 In making of steel, phosphorous separates as :

(A) Slag. Ca3(PO4)2 (B) volatile, P2O5 (C) slag, FePO4 (D) Ca3P2
Q.215 Incorrect statement regarding silver extraction process is :

(A) When the lead-silver composition is rich in silver, lead is removed by the cupellation process.
(B) When lead-silver composition is rich in lead, most of lead is removed by Pattinson's process.
(C) Zinc forms an alloy with lead, from which lead is separated by distillation
(D) Zinc dissolves silver, from which zinc is separated by distillation.
Q.216 Which process is based on Distribution law

(A) Pattinson's process (B) Parke's process (C) Kroll process (D) Moisson process
Q.217 During poling which ofthe following oxide(s) is/are not reduced by hydrocarbons.
(A) SnO2 (B) Fe2O3 (C) Cu2O (D) both A and C
Q.218 Ultrapure form of Si and Ge are obtained from.

(A) zone-refining (B) electrorefining
(C) Van-Arkel's process (D) cupellation process
Q.219 The metal for which, its propertyof forming of volatile complex is used for its purification.
(A) Cobalt (B) Nickel (C) Vanadium (D) Iron
Q.220 In the purification of aluminium by Hoope's process, impurities of silicon and copper are added to the
molten impure aluminium in order to :
(A) make the melt conducting (B) reduce CaO into Ca
(C) smooth deposition of aluminium ion (D) make the melt heavier
Q.221 In electrorefining of metal, the anode is made of thick plate of impure metal and this method is not used
for 1 refining of :
(A) Silver (B) Copper (C)Aluminium (D) Gold
Q.222 % of silver in 'german silver' is

(A) 0 (B)80 (C) 90 (D) 10
Metallurgy
Q.223 Which method of purification is presented by the following reactions?
Ti  2 I 2 500
 K
 TiI 4 1675
 K
 Ti  2 I 2
(Impure) (Pure)
(A) Cupellation (B) Polling (C) Van Arkel (D) Zone refining
Q.224 Which of the following metals may be present in the anode mud during electrorefining of copper?
I. Gold ; II. Iron ; III. Silver ; IV. magnesium
(A) I and II (B) II and IV (C) I and III (D) III and IV
Q.225 Mercury is purified by:

(A) Leaching (B) Distillation (C) Cupellation (D) Vapour phase refining
Q.226 Which is not correctly matched :

(A) Spiegleisan : Mn + Fe+C (B) Dow's sea water process : Ca(OH)2
(C) Parke's process : Ag (D) Liquation : Spelter (Impure Zn)
Q.227 Silver and gold are often obtained as valuable by-products during:
(A) Smelting (B) Electrolytic refining
(C) Zone refining (D) Iron making
Q.228 Extraction of pure Zn metal from its sulphide ore does not involve
(A) Roasting (B) Distillation (C) Self reduction (D) Rapid Cooling
Q.229 Which of the following match is incorrect
Extraction Method Metal(s)
(A) Self reduction Hg, Pb
(B) Electrolytic reduction Na, Al
(C) Hydrometallurgy Pb, Zn
(D)Alumino-thermite reduction Mn, Cr
Q.230 Which of the following metal is commerciallyextracted byPyrometallurgy

(A)Ag (B)Al (C) Cu (D) Mg
Metallurgy
EXERCISE-2
SECTION-A
(JEE Main Previous Year's Questions)
Q.1 Aluminium is industrially prepared by : [AIEEE- 2002]

(A) Fused cryolite (B) Bauxite ore (C) Alumina (D) Borax
Q.2 Which one of the following ores is best concentrated by froath-flotation method ? [AIEEE 2004]
(A) Magnetite (B) Cassiterite (C) Galena (D) Malachite
Q.3 During the process of electrolytic refining of copper, some metals present as impurity settle as 'anode
mud'. These are – [AIEEE 2005]
(A) Pb and Zn (B) Sn and Ag (C) Fe and Ni (D) Ag and Au
Q.4 Heating mixture of Cu2O and Cu2S will give – [AIEEE 2005]
(A) Cu + SO3 (B) Cu + SO2 (C) Cu2SO3 (D)CuO + CuS
Q.5 Which of the following factors is of no significance for roasting sulphide ores to the oxides and not
subjecting the sulphide ores to carbon reduction directly [AIEEE 2008]
(A) Metal sulphides are thermodynamically more stable than CS2
(B) CO2 is thermodynamically more stable than CS2
(C) Metal sulphides are less stable than the corresponding oxides
(D) CO2 is more volatile than CS2
Q.6 Which method of purification is represented by the following equation : [AIEEE 2012]
Ti(s) + 2I2(g) 523
 K
 TiI4 (g) 1700
 K
 Ti(s) + 2I2(g)
(A) Poling (B) VanArkel (C) Zone refining (D) Cupellation
Q.7 The metal that cannot be obtained by electrolysis of an aqueous solution of its salts is:
(A) Ca (B) Cu (C) Cr (D)Ag [JEE Main 2014]
Q.8 Which series of reactions correctly represents chemical relations related to iron and its compound ?
(A) Fe O2 , FeO dil
heat
H  FeSO4 heat
2SO 4
 Fe [JEE Main 2014]
(B) Fe Cl
2 , FeCl3 heat
heat
  FeCl2 
,air Zn Fe
(C) Fe O2 , 600C 700C

 Fe3O4 CO
heat
,  FeO CO
,  Fe
(D) Fe dil
H  FeSO4 H2SO
2SO 4
 Fe2(SO4)3 heat
,O 2
4   Fe
Metallurgy
Q.9 In the context of the Hall-Heroult process for the extraction ofAl, which of the following statements is
false? [JEE Main 2015]
3+
(A) Al is reduced at the cathode to form Al
(B) Na3AlF6 serves as the electrolyte
(C) CO and CO2 are produced in this process
(D)Al2O3 is mixed with CaF2 which lowers the melting point of the mixture and brings conductivity
Q.10 Galvanization is applying a coating of : [JEE Main 2016]

(A) Zn (B) Pb (C) Cr (D) Cu
Q.11 Which one of the following ores is best concentrated by froth floatation method? [JEE Main 2016]
(A) Malachite (B) Magnetite (C) Siderite (D) Galena
Q.12 When metal 'M' is treated with NaOH, a white gelatinous precipitate 'X' is obtained which is soluble in
excess of NaOH. Compound 'X' when heated strongly gives an oxide which is used in chromatography
as an adsorbent. The metal 'M' is : [JEE Main 2018]
(A)Al (B) Fe (C) Zn (D) Ca
Metallurgy
SECTION-B
(JEE ADVANCED Previous Year's Questions)
Q.1 Answer the following questions briefly: [1987]
(i) What is the actual reducing agent of haematite in blast furance?
(ii) Give the equations for the recovery of lead from galena by air reduction.
(iii) Why is sodium chloride added during electrolysis of fused anhydrous magnesium chloride?
(iv) Whycopper metal is not used for the recoveryof metallic silver from complex [Ag(CN)2]– explain.
(v) Why is chalcocite roasted and not calcinated during recovery of copper?
Q.2 In extractive metallurgyof zinc partial fusion of ZnO with coke is called ______ and reduction of the ore
to the molten metal is called ________ (smelting, calcining, roasting, sintering). [1988]
Q.3 Write balanced equation for "the extraction of copper from copper pyrites by self reduction." [1990]
Q.4 Give briefly the isolation of magnesium from sea water by the Dow's process. Give equations for the
steps involved. [1993]
Q.5 Give reasons for the following: [1994]
"Although aluminium is above hydrogen in the electrochemical series, it is stable in air and water."
Q.6 Give balanced equations for the following: [1998]
" Extraction of silver from silver glance by cyanide process."
Q.7 In the commercial electrochemical process for aluminium extraction, the electrolyte used as: [1999]
(A)Al(OH)3 in NaOH solution (B) an aqueous solution of Al2(SO4)3
(C) a molten mixture ofAl2O3 and Na3AlF6 (D) a molten mixture ofAlO(OH) andAl(OH)3
Q.8 The chemical process in the production of steel from haematite ore involve: [2000 Qualifying]
(A) reduction (B) oxidation
(C) reduction followed by oxidation (D) oxidation followed by reduction
Q.9 The chemical composition of "slag" formed during the smelting process in the extraction of copper is:
[2001 Qualifying]
(A) Cu2O + FeS (B) FeSiO3 (C) CuFeS2 (D) Cu2S + FeO
Q.10 Which of the following processes is used in extractive metallurgyof magnesium? [2002 Qualifying]
(A) Fused salt electrolysis (B) Self reduction
(C)Aqueous solution electrolysis (D) Thermite reduction
Q.11 In the process of extraction of gold,
Roasted gold ore + CN– + H2O O 2 [X] + OH–
[X] + Zn  [Y] + Au
Identify the complexes [X] and [Y] : [2003 Qualifying]
–
(A) X = [Au(CN)2] , Y = [Zn(CN)4] 2– (B) X = [Au(CN)4] , Y = [Zn(CN)4]2–
3–
–
(C) X = [Au(CN)2] , Y = [Zn(CN)6] 4– (D) X = [Au(CN)4]– , Y = [Zn(CN)4]2–
Q.12 The methods chiefly used for the extraction of lead and tin from their ores are respectively: [2004]
(A) self reduction and carbon reduction (B) self reduction and electrolytic reduction
(C) carbon reduction and self reduction (D) cyanide process and carbon reduction
Metallurgy
Q.13 Which ore contains both iron and copper ? [2004]
(A) Cuprite (B) Chalcocite (C) Chalcopyrite (D) Malachite
Q.14 Match the extraction processes listed in column I with metals listed in column II. [2006]
Column I Column II
(A) Self reduction (P) Lead
(B) Carbon reduction (Q) Silver
(C) Complex formation and (R) Copper
displacement by metal
(D) Decomposition o iodide (S) Boron
Q.15 Extraction for zinc from zinc blende is achieved by: [2007]
(A) electrolytic reduction
(B) roasting followed by reduction with carbon
(C) roasting followed by reduction with another metal
(D) roasting followed by self-reduction
Q.16 Native silvermetal forms a water solublecomplex with a dilute aqueous solution of NaCN inthe presence of
(A) nitrogen (B) oxygen (C) carbon dioxide (D) argon [2008]
Q.17 Match the conversions in Column I with the type(s) of reaction(s) given in Column II. Indicate your
answer by darkening the appropriate bubbles of the 4 × 4 matrix given in the ORS. [2008]
Column I Column II
(A) PbS  PbO (P) Roasting
(B) CaCO3  CaO (Q) Calcination
(C) ZnS  Zn (R) Carbon reduction
(D) Cu2S  Cu (S) Self reduction
Paragraph for Questions 18 to 20

Copper is the most noble of the first row transition metals and occurs in small deposits in several countries.
Ores of copper include chalcanthite (CuSO4·5H2O), atacamite (Cu2Cl(OH)3), cuprite (Cu2O), copper
glance (Cu2S) and malachite (Cu2(OH)2CO3). However, 80% of the world copper production comes
from the ore chalcopyrite (CuFeS2). The extraction of copper from chalopyrite involved partial roasting,
removal of iron and self-reduction.
Q.18 Partial roasting of chalcopyrite produces [2010]
(A) Cu2S and FeO (B) Cu2O and FeO
(C) CuS and Fe2O3 (D) Cu2O and Fe2O3
Q.19 Iron is removed from chalcopyrite as [2010]

(A) FeO (B) FeS (C) Fe2O3 (D) FeSiO3
Q.20 In self-reduction, the reducing species is [2010]

(A) S (B) O2– (C) S2– (D) SO2
Q.21 Extraction of metal from the ore cassiterite involves [2011]

(A) carbon reduction of an oxide ore (B) self-reduction of a sulphide ore
(C) removal of copper impurity (D) removal of iron impurity
Metallurgy
Q.22 Oxidation states of the metal in the minerals haematite and magnetite, respectively, are [2011]
(A) II, III in haematite and III in magnetite (B) II, III in haematite and II in magnetite
(C) II in haematite and II, III in magnetite (D) III in haematite and II, III in magnetite
Q.23 In the cyanide extraction process of silver from argentite ore, the oxidizing and reducing agents used are:
(A) O2 and CO respectively (B) O2 and Zn dust respectively [2012]
(C) HNO3 and Zn dust respectively (D) HNO3 and CO respectively
Q.24 Sulfide ores are common for the metals : [JEEAdvance 2013]
(A) Ag, Cu and Pb (B) Ag, Cu and Sn
(C) Ag, Mg and Pb (D) Al, Cu and Pb
Q.25 The carbon-based reduction method is NOT used for the extraction of [JEEAdvance 2013]
(A) tin from SnO2 (B) iron from Fe2O3
(C) aluminium fromAl2O3 (D) magnesium from MgCO3 · CaCO3
Q.26 Upon heating with Cu2S, the reagent(s) that give copper metal is/are [JEEAdvance 2014]
(A) CuFeS2 (B) CuO
(C) Cu2O (D) CuSO4
Q.27 Copper is purified by electrolytic refining of blister copper. The correct statement(s) about this process
is(are): [JEEAdvance 2015]
(A) Impure Cu strip is used as cathode
(B) Acidified aqueous CuSO4 is used as electrolyte
(C) Pure Cu deposits at cathode
(D) Impurities settle as anode - mud
Q.28 Match the anionic species given in Column I that are present in the ore(s) given in Column II
Column I Column II [JEEAdvance 2015]
(A) Carbonate (P) Siderite
(B) Sulphide (Q) Malachite
(C) Hydroxide (R) Bauxite
(D) Oxide (S) Calamine
(T) Argentite
Q.29 Extraction of copper from copper pyrite (CuFeS2) involves [JEEAdvance 2016]
(A) crushing followed by concentration of the ore by froth-flotation
(B) removal of iron as slag
(C) self-reduction step to produce 'blister copper' following evolution of SO2
(D) refining of 'blister copper' by carbon reduction
Q.30 Galena (an ore) is partially oxidized by passing air through it at high temperature.After some time, the
passage of air is stopped, but the heating is continued in a closed furnace such that the contents undergo
self-reduction. The weight (in kg) of Pb produced per kg of O2 consumed is ____.
(Atomic weights in g mol–1: O = 16, S = 32, Pb = 207) [JEEAdvance 2018]
Metallurgy
EXERCISE-3
(NCERT Exampler)
I. Multiple choice questions (Type-I)
Q.1 In the extraction of chlorine by electrolysis of brine ________.
(A) oxidation of Cl¯ ion to chlorine gas occurs. (B) reduction of Cl¯ ion to chlorine gas occurs.
(C) For overall reaction G has negative value. (D) a displacement reaction takes place.
Q.2 When copper ore is mixed with silica, in a reverberatory furnace copper matte is produced. The copper
matte contains ______.
(A) sulphides of copper (II) and iron (II) (B) sulphides of copper (II) and iron (III)
(C) sulphides of copper (I) and iron (II) (D) sulphides of copper (I) and iron (III)
Q.3 Which of the following reactions is an example of autoreduction ?
(A) Fe3O4 + 4CO  3Fe + 4CO2 (B) Cu2O + C  2Cu + CO
1 1
(C) Cu2+ (aq) + Fe(s)  Cu(s) + Fe2+ (aq) (D) Cu2O + Cu2S  3Cu + SO2
2 2
Q.4 A number of elements are available in earth's crust but most abundant elements are _______.
(A) Al and Fe (B) Al and Cu (C) Fe and Cu (D) Cu and Ag
Q.5 Zone refining is based on the principle that __________.
(A) impurities of low boiling metals can be separated by distillation.
(B) impurities are more soluble in molten metal than in solid metal.
(C) different components of a mixture are differently adsorbed on an adsorbent.
(D) vapours of volatile compound can be decomposed in pure metal.
Q.6 In the extraction of copper from its sulphide ore, the metal is formed by the reduction of Cu2O with
(A) FeS (B) CO (C) Cu2S (D) SO2
Q.7 Brine is electrolysed by using inert electrodes. The reaction at anode is _______.
1 
(A) Cl¯(aq.)  Cl2 (g) + e– ; E cell  1.36 V
2
(B) 2H2O (l)  O2 (g) + 4H+ + 4e– ; 
E cell  1.23 V
(C) Na+ (aq.) + e–  Na(s) ; 

E cell  2.71 V
1
(D) H+ (aq.) + e–  H (g) ; 
E cell  0.00 V
2 2
Q.8 In the metallurgyof aluminium __________.
(A) Al3+ is oxidised toAl (s).
(B) graphide anode is oxidised to carbon monoxide and carbon dioxide.
(C) oxidation state of oxygen changes in the reaction at anode
(D) oxidation state of oxygen changes in the overall reaction involved in the process.
Q.9 Electrolytic refining is used to purifywhich of the following metals ?
(A) Cu and Zn (B) Ge and Si (C) Zr and Ti (D) Zn and Hg
Q.10 Extraction of gold and silver involves leaching the metal with CN¯ ion. The metal is recovered by _____.
(A) displacement of metal by some other metal from the complex ion.
(B) roasting of metal complex
(C) calcination followed by roasting
(D) thermal decomposition of metal complex.
Metallurgy
Note : Answer the questions 11–13 on the basis of figure.
–200
eO
2F


O2
–300 Fe+
G¯ / kJ mol of O2 
2
D
A E C+O2 CO2
–400 B
O 2
–1
2C


2
O
–500 O+ 2C
2C +O
2

2C
O
–600
–700
0 400 800 1200 1600 2000
Temperature (°C) 
Figure 6.1
Q.11 Choose the correct option of temperature at which carbon reduces FeO to iron and produces CO.
(A) Below temperature at point A
(B)Approximately at the temperature corresponding to point A.
(C) Above temperature at point Abut below temperature at point D.
(D)Above temperature at point A.
Q.12 Below point 'A' FeO can _______.
(A) be reduced by carbon monoxide only.
(B) be reduced by both carbon monoxide and carbon
(C) be reduced by carbon only
(D) not be reduced by both carbon and carbon monoxide.
Q.13 For the reduction of FeO at the temperature corresponding to point D, which of the following statements
is correct?
(A) G value for the overall reduction reaction with carbon monoxide is zero.
(B) G value for the overall reduction reaction with a mixture of 1 mol carbon and 1 mol oxygen is
positive.
(C) G value for the overall reduction reaction with a mixture of 2 mol carbon and 1 mol oxygen will be
positive.
(D) G value for the overall reduction reaction with carbon monoxide is negative.
II. Multiple choice questions (Type-II)

Note : In the following questions two or more options may be correct.
Q.14 At the temperature corresponding to which of the point in figure 6.1, FeO will be reduced to Fe by
coupling the reaction 2FeO  2Fe + O2 with all of the following reactions ?
(a) C + O2  CO2
(b) 2C + O2  2CO
(c) 2CO + O2  2CO2
(A) Point A (B) Point B (C) Point D (D) Point E
Metallurgy
Q.15 Which of the following options are correct ?
(A) Cast iron is obtained by remelting pig iron with scrap iron and coke using hot air blast.
(B) In extraction of silver, silver is extracted as cationic complex.
(C) Nickel is purified by zone refining.
(D) Zr and Ti are purified by Van Arkel method.
Q.16 In the extraction of aluminium by Hall-Heroult process, purifiedAl2O3 is mixed with CaF2 to
(A) lower the melting point ofAl2O3 (B) increase the conductivityof molten mixture
(C) reduceAl3+ into Al(s) (D) acts as catalyst.
Q.17 Which of the following statements is correct about the role of substances added in the froth floation
process ?
(A) Collectors enhance the non-wettability of the mineral particles
(B) Collectors enhance the wettability of gangue particles.
(C) By using depressants in the process two sulphide ores can be separated
(D) Froth stabilisers decrease wettability of gangue.
Q.18 In the Froth Floatation process, zinc sulphide and lead sulphide can be separated by _______.
(A) using collectors (B) adjusting the proportion of oil to water
(C) using depressant (D) using froth stabilisers
Q.19 Common impurities present in bauxite are _______.
(A) CuO (B) ZnO (C) Fe2O3 (D) SiO2
Q.20 Which of the following ores are concentrated by froth floation ?
(A) Haematite (B) Galena (C) Copper pyrites (D) Magnetite
Q.21 Which of the following reactions occur during calcination ?
11
(A) CaCO3  CaO + CO2 (B) 2FeS2 + O  Fe2O3 + 4SO2
2 2
3
(C) Al2O3.xH2O  Al2O3 + xH2O (D) ZnS + O  ZnO + SO2
2 2
Q.22 For the metallurgical process of which of the ores calcined ore can be reduced by carbon ?
(A) haematite (B) calamine (C) iron pyrites (D) sphalerite
Q.23 The main reactions occuring in blast furnace during extraction of iron from haematite are ______.
(A) Fe2O3 + 3CO  2Fe + 3CO2 (B) FeO + SiO2  FeSiO3
(C) Fe2O3 + 3C  2Fe + 3CO (D) CaO + SiO2  CaSiO3
Q.24 In which of the following method of purification, metal is converted to its volatile compound which is
decomposed to give pure metal?
(A) heating with stream of carbon monoxide. (B) heating with iodine
(C) liquation (D) distillation
Q.25 Which of the following statements are correct ?

(A) Adepressant prevents certain type of particle to come to the froth.
(B) Copper matte contains Cu2S and ZnS
(C) The solidified copper obtained from reverberatoryfurnace has blistered appearance due to evolution
of SO2 during the extraction.
(D) Zinc can be extracted by self-reduction
Metallurgy
Q.26 In the extraction of chlorine from brine ______.
(A) G for the overall reaction is negative. (B) G for the overall reaction is positive.
(C)E for overall reaction has negative value. (D)E for overall reaction has positive value.
III. Short Answer Type
Q.27 Why is an external emf of more than 2.2 V required for the extraction of Cl2 from brine?
Q.28 At temperatures above 1073 K coke can be used to reduce FeO to Fe. How can you justify this
reduction with Ellingham diagram ?
Q.29 Wrought iron is the purest form of iron. Write a reaction used for the preparation of wrought iron from
cast iron. How can the impurities of sulphur, silicon and phosphorus be removed from cast iron?
Q.30 How is copper extracted from low grade copper ores?
Q.31 Write two basic requirements for refining of a metal by Mond process and byVanArkel Method.
Q.32 Althought carbon and hydrogen are better reducing agents but they are not used to reduce metallic
oxides at high temperatures. Why?
Q.33 How do we separate two sulphide ores by Froth Floatation Method? Explain with an example.
Q.34 The purest form of iron is prepared by oxidising impurities from cast iron in a reverberatory furnace.
Which iron ore is used to line the furnace ? Explain by giving reaction.
Q.35 The mixture of compounds A and B is passed through a column of Al2O3 by using alcohol as eluant.
CompoundA is eluted in preference to compound B. Which of the compounds Aor B, is more readily
adsorbed on the column ?
Q.36 Why is sulphide ore of copper heated in a furnace after mixing with silica ?
Q.37 Why are sulphide ores converted to oxide before reduction ?
Q.38 Which method is used for refining Zr and Ti? Explain with equation.
Q.39 What should be the considerations during the extraction of metals by electrochemical method ?
Q.40 What is the role of flux in metallurgical processes ?
Q.41 How are metals used as semiconductors refined ? What is the principle of the method used ?
Q.42 Write down the reactions taking place in Blast furnace related to the metallurgy of iron in the temperature
range 500 – 800 K.
Q.43 Give two requirements for vapour phase refining.
Q.44 Write the chemical reactions involved in the extraction of gold by cyanide process.Also give the role of
zinc in the extraction.
IV. Matching Type
Q.45 Match the items of Column I with items of Column II and assign the correct code:
Column I Column II
(A) Pendulum (1) Chrome steel
(B) Malachite (2) Nickel steel
(C) Calamine (3) Na2AlF6
(D) Cryolite (4) CuCO3.Cu(OH)2
(5) ZnCO3
Codes:
(A) A (1) B (2) C (3) D (4) (B) A (2) B (4) C (5) D (3)
(C) A (2) B (3) C (4) D (5) (D) A (4) B (5) C (3) D (2)
Metallurgy
Column I Column II
(A) Coloured bands (1) Zone refining
(B) Impure metal to volatile complex (2) Fractional distillation
(C) Purification of Ge and Si (3) Mond process
(D) Purification of mercury (4) Chromatography
(5) Liquation
Codes:
(A) A (1) B (2) C (4) D (5) (B) A (4) B (3) C (1) D (2)
(C) A (3) B (4) C (2) D (1) (D) A (5) B (4) C (3) D (2)
Q.47 Match items of Column I with the items of Column II and assign the correct code:
Column I Column II
(A) Cyanide process (1) Ultrapure Ge
(B) Froth Floatation process (2) Dressing of ZnS
(C) Electrolytic reduction (3) Extraction ofAl
(D) Zone refining (4) Extraction ofAu
(5) Purification of Ni
Codes:
(A) A (4) B (2) C (3) D (1) (B) A (2) B (3) C (1) D (5)
(C) A (1) B (2) C (3) D (4) (D) A (3) B (4) C (5) D (1)
Q.48 Match the items of Column I with the items of Column II and assign the correct code:
Column I Column II
(A) Sapphire (1) Al2O3
(B) Sphalerite (2) NaCN
(C) Depressant (3) Co
(D) Corundum (4) ZnS
(5) Fe2O3
Codes:
(A) A (3) B (4) C (2) D (1) (B) A (5) B (4) C (3) D (2)
(C) A (2) B (3) C (4) D (5) (D) A (1) B (2) C (3) D (4)
Column I Column II
(A) Blisterred Cu (1) Aluminium
(B) Blast furnace (2) 2Cu2O + Cu2S  6Cu + SO2
(C) Reverberatory furnace (3) Iron
(D) Hall-Heroult process (4) FeO + SiO2  FeSiO3
(5) 2Cu2S + 3O2  2Cu2O + 2SO2
Codes:
(A) A (2) B (3) C (4) D (1) (B) A (1) B (2) C (3) D (5)
(C) A (5) B (4) C (3) D (2) (D) A (4) B (5) C (3) D (2)
Metallurgy
V. Assertion and Reason Type
(A) Both assertion and reason are true, and reason is the correct explanation of the assertion.
(B) Both assertion and reason are true but reason is not the correct explanation of assertion.
(C)Assertion is not true but reason is true.
(D) Both assertion and reason are false.
Q.50 Assertion : Nickel can be purified by Mond process.
Reason : Ni(CO)4 is a volatile compound which decomposes at 460 K to give pure Ni.
Q.51 Assertion : Zirconium can be purified byVanArkel method.

Reason : ZrI4 is volatile and decomposes at 1800 K.
Q.52 Assertion : Sulphide ores are concentrated by Froth Flotation method.

Reason : Cresols stabilise the froth in Froth Flotation method.
Q.53 Assertion : Zone refining method is very useful for producing semiconductors.
Reason : Semiconductors are of high purity.
Q.54 Assertion : Hydrometallurgy involves dissolving the ore in a suitable reagent followed by precipitation
by a more electropositive metal.
Reason : Copper is extracted by hydrometallurgy.
VI. Long Answer type

Q.55 Explain the following:
(a) CO2 is a better reducing agent below 710 K whereas CO is a better reducing agent above
710 K.
(b) Generally sulphide ores are converted into oxides before reduction.
(c) Silica is added to the sulphide ore of copper in the reverberatory furnace
(d) Carbon and hydrogen are not used as reducing agents at high temperatures.
(e) Vapour phase refining method is used for the purification of Ti.
Metallurgy
ANSWER KEY
EXERCISE-1
Q.1 C Q.2 A Q.3 A Q.4 B Q.5 C Q.6 D Q.7 B
Q.8 D Q.9 A Q.10 D Q.11 A Q.12 B Q.13 A Q.14 D
Q.15 A Q.16 A Q.17 D Q.18 C Q.19 B Q.20 A Q.21 B
Q.22 D Q.23 A Q.24 B Q.25 D Q.26 B Q.27 C Q.28 A
Q.29 C Q.30 D Q.31 C Q.32 A Q.33 D Q.34 D Q.35 D
Q.36 D Q.37 B Q.38 D Q.39 C Q.40 B Q.41 D Q.42 D
Q.43 C Q.44 C Q.45 D Q.46 B Q.47 A Q.48 B Q.49 A
Q.50 C Q.51 B Q.52 C Q.53 A Q.54 B Q.55 A Q.56 B
Q.57 A Q.58 B Q.59 B Q.60 C Q.61 B Q.62 B Q.63 D
Q.64 B Q.65 B Q.66 D Q.67 B Q.68 A Q.69 B Q.70 A
Q.71 A Q.72 D Q.73 B Q.74 A Q.75 C Q.76 D Q.77 D
Q.78 B Q.79 D Q.80 A Q.81 B Q.82 C Q.83 C Q.84 B
Q.85 D Q.86 A Q.87 B Q.88 B Q.89 D Q.90 A Q.91 B
Q.92 B Q.93 D Q.94 D Q.95 D Q.96 D Q.97 B Q.98 D
Q.99 D Q.100 B Q.101 C Q.102 C Q.103 C Q.104 D Q.105 C
Q.106 C Q.107 B Q.108 B Q.109 D Q.110 A Q.111 D Q.112 D
Q.113 C Q.114 B Q.115 B Q.116 A Q.117 B Q.118 C Q.119 A
Q.120 B Q.121 A Q.122 B Q.123 A Q.124 B Q.125 C Q.126 A
Q.127 A Q.128 B Q.129 C Q.130 D Q.131 C Q.132 C Q.133 A
Q.134 C Q.135 D Q.136 B Q.137 D Q.138 A Q.139 C Q.140 D
Q.141 A Q.142 B Q.143 C Q.144 C Q.145 D Q.146 C Q.147 C
Q.148 B Q.149 C Q.150 D Q.151 D Q.152 C Q.153 D Q.154 C
Metallurgy
Q.155 B Q.156 C Q.157 B Q.158 A Q.159 C Q.160 C Q.161 C
Q.162 B Q.163 B Q.164 C Q.165 B Q.166 D Q.167 D Q.168 C
Q.169 C Q.170 A Q.171 B Q.172 C Q.173 B Q.174 D Q.175 B
Q.176 D Q.177 D Q.178 A Q.179 C Q.180 B Q.181 A Q.182 D
Q.183 C Q.184 D Q.185 C Q.186 A Q.187 B Q.188 B Q.189 D
Q.190 A Q.191 B Q.192 B Q.193 A Q.194 D Q.195 B Q.196 B
Q.197 B Q.198 D Q.199 C Q.200 B Q.201 C Q.202 B Q.203 C
Q.204 C Q.205 D Q.206 A Q.207 D Q.208 C Q.209 C Q.210 B
Q.211 B Q.212 C Q.213 C Q.214 A Q.215 C Q.216 B Q.217 B
Q.218 A Q.219 B Q.220 D Q.221 C Q.222 A Q.223 C Q.224 C
Q.225 B Q.226 D Q.227 B Q.228 C Q.229 C Q.230 C
EXERCISE-2
SECTION-A
Q.1 B Q.2 C Q.3 D Q.4 B Q.5 C Q.6 B Q.7 A
Q.8 C Q.9 B Q.10 A Q.11 D Q.12 A
SECTION-B
Q.2 sintering , smelting Q.7 C Q.8 C Q.9 B Q.10 A Q.11 A
Q.12 A Q.13 C Q.14 (A) P, R ; (B) P ; (C) Q ;(D) S Q.15 B Q.16 B
Q.17 (A) P; (B) Q; (C) P,R (D) P,S Q.18 A Q.19 D Q.20 C Q.21 ACD
Q.22 D Q.23 B Q.24 A Q.25 CD Q.26 BCD Q.27 BCD
Q.28 (A) PQS (B) T (C) QR (D) R Q.29 ABC Q.30 6.47
EXERCISE-3
Q.1 C Q.2 C Q.3 D Q.4 A Q.5 B Q.6 C Q.7 A
Q.8 B Q.9 A Q.10 A Q.11 D Q.12 A Q.13 A Q.14 BD
Q.15 AD Q.16 AB Q.17 AC Q.18 BC Q.19 CD Q.20 BC Q.21 AC
Q.22 AB Q.23 AD Q.24 AB Q.25 AC Q.26 BC

Metallurgy
Q.27 For the reaction
2Cl¯(aq) + 2H2O (l)  2OH¯ (aq) + H2(g) + Cl2 (g)
Value of G¯ is + 422 kJ. Using the equation G¯ = – nFE¯ the value of E¯ comes out to be – 2.2 V.
Therefore extraction of Cl2 from brine will require an external emf of greater than 2.2 V.
Q.28 As per Ellingham diagram at temperatures greater than 1073 K

G (C, CO) < G (Fe, FeO). Hence coke can reduce FeO to Fe.
Q.29 Fe2O3 + 3C  2Fe + 3CO

Limestone is added as flux and sulphur, silicon and phosphorus change to their oxides and pass into the
slag.
Q.30 Copper is extracted by hydrometallurgy from low grade copper ores. It is leached out using acid or
bacteria. The solution containing Cu2+ is treated with scrap iron, Zn or H2.
Cu2+ (aq) + H2 (g)  Cu(s) + 2H+ (aq)
Cu2+ + Fe(s)  Fe2+ (aq) + Cu(s)
Q.31 Basic requirements for both processes are :

(i) The metal should form a volatile compound with an available reagent.
(ii) The volatile compound should be easily decomposable, so that recovery of metal is easy.
Q.32 It is because at high temperature carbon and hydrogen react with metals to form carbides and hydrides
respectively.
Q.33 Two sulphide ores can be separated by adjusting proportion of oil to water or by using depressants. For
example, in the case of an ore containing ZnS and PbS, the depressant NaCN is used. It forms complex
with ZnS and prevents it form coming with froth but PbS remains with froth.
Q.34 Haematite
Fe2O3 + 3C  2Fe + 3CO
Q.35 Since compound 'A' comes out before compound 'B', the compound 'B' is more readily adsorbed on
column.
Q.36 Iron oxide present as impurity in sulphide ore of copper forms slag which is iron silicate and copper is
produced in the form of copper matte.
FeO + SiO2  FeSiO3
Q.37 Sulphides are not reduced easily but oxides are easily reduced.
Q.38 Van Arkel method is used for refining Zr and Ti. In this method crude metal is heated with iodine.
Zr + 2I2  ZrI4
1800 K
ZrI4   Zr + 2I2
Q.39 Generally two things are considered so that proper precautions can be taken :
(i) reactivity of metal produced.
(ii) suitability of electrodes.
Metallurgy
Q.40 Flux is used for making the molten mass more conducting.
Q.41 Semiconducting metal is produced by zone refining method which is based on the principle that the
impurities are more soluble in melt than in the solid state of metals.
Q.42 3Fe2O3 + CO  2Fe3O4 + CO2
Fe3O4 + 4CO  3Fe + 4CO2
Fe2O3 + CO  2FeO + CO2
Q.43 (i) The metal should form a volatile compound with available reagent.
(ii) The volatile compound should be easily decomposable so that the recovery is easy.
Q.44 4Au (s) + 8CN¯ (aq) + 2H2O (aq) + O2 (g)  4 [Au(CN)2]¯ (aq) + 4OH¯ (aq)
2[Au(CN)2]¯ (aq) + Zn(s)  2Au(s) + [Zn(CN)4]2–(aq)
In this reaction zinc acts as a reducing agent.
Q.45 B Q.46 B Q.47 A Q.48 A Q.49 A Q.50 A Q.51 A
Q.52 B Q.53 B Q.54 B
Q.55 (a) Hint : Use Ellingham diagram

(b) Hint : Oxides are easier to reduce. See Ellingham diagram.
(c) Hint : Sulphide ore of copper contains iron as impurity which is removed as iron silicate (slag)
FeO + SiO2  FeSiO3 (slag)
(d) Hint : Carbon and hydrogen react with metals at high temperature to form carbides and hydrides
respectively.
(e) Hint : Ti reacts with iodine to form volatile TiI4 which decomposes at high temperature to give
extra pure titanium.
Metallurgy
NOTES

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JEE (MAIN+ADVANCED)

GENERAL PRINCIPLES & PROCESSES OF

Pyrometallury Hydro metallurgy Electrometallurgy

GENERAL STEPS INVOLVED IN METALLURGY

COMMON STEPS INVOLVED IN METALLURGY

(II) CONCENTRATION (DRESSING) OF THE ORE

Magnetic Non Magnetic

 It is employed for sulphide ores.

Al2O3(s) + 2NaOH(aq) + 3H2O(l)   2Na[Al(OH)4](aq) + Fe2O3 

(ii) MacArthur-Forest cyanide process :

(III) WORKING OF THE CONCENTRATED ORE

Air & Oil

(IV) CONVERSION OFTHE OXIDE TO METALLIC FORM (REDUCTION PROCESS)

+ve T(K) (TS >H) T(K)

(b) Reduction by heating in air (Auto-reduction) /Self reduction

PbO  PbSiO 3 CaO

(c) Reduction by Carbon / Carbon Mono oxide :

CaO + SiO2 fuse

(ii) Reduction of Fe2O3 in Blast Furnace :

Figure : Blast Furnace

 Reduction zone (200 - 700°C)

 Slag formation zone (700 - 1200°C)

 Fusion zone ( 1200 – 1500°C)

(iii) Carbon Reduction of Black tin :

CaO + SiO2 fuse

(d) Reduction using more active Metal

 Aluminium acts as reducing agent due to its high electropositive nature.

(ii) Kroll Process :

(e) Electrolytic reduction (Electro-metallurgy)

Molten : Al 2O3 + Na 3AlF6

Reactions : Na3Al F6  3NaF + AlF3

(ii) EXRACTION OF SODIUM (Down’s cell process) :

~ ~~ ~~~~ ~~ ~ ~ ~~~ ~ ~~~

Downs cell for the production of sodium

(iii) Electrolysis of fused anhydrous MgCl2 :

Molten matte +Sand

Bessemer converter of copper

(g) Zone Refining :

(h) Vapour phase refining

(i) Park’s Process :

(j) Pattinsons Process :

S.No. Metal Anode Cathode Electrolyte

Iron cell Na3 AlF6 + CaF2

Cu, Al, Si alloy anode Carbon

Hoope’s process for purification

(I) EXTRACTION OF GOLD

(II) EXTRACTION OF SILVER

ImpureAg is purified by Electrolytic refining method or byAmalgamation.

(III) EXTRACTION OF COPPER

Roasting Smelting matte

Low grade copper can be extracted by hydrometallurgical process also.

(VI) EXTRACTION OF LEAD

Roasting Self Refining

Roasting Reduction Refining

Concentration Calcination followed

scrap iron ,carbon and air

Fast cooling Slow cooling

White cast iron

Manufacturing of steel from cast iron :

Heating Treatment of steel

Surface Treatment of steel / Case- Hardening

(VII) EXTRACTION OF ZINC

Zinc Blende Froath floatation

Impure Zn is purified by Electrolytic refining method or bydistillation.

~ ~ ~ ~~~ ~ ~~~