METALLURGY

Metallurgy is the process of extraction of pure metals from their respective ores.

Mineral:- Naturally occurring compounds of the metal found in the earth’s crust are
called minerals.

Ore:- Natural occurring mineral from which metals can be extracted profitably and
conveniently.

Matrix:- The rocky impurities including silica, mud etc., associated with the ore are
called gangue or matrix.

Flux:- The substance added to the ore to remove the gangue in the form of a fusible
compound called slag.

Examples of ores:-

Iron ores Aluminium ores Zinc ores

Haematite (Fe2O3) Bauxite ( Al2O3.2H2O) Zinc Blende (ZnS)

Iron pyrites (FeS2) Cryolite (Na3AlF6) Calamine (ZnCO3)

Magnetite (Fe3O4) Corundum (Al2O3) Zincite ( ZnO)

Spathic Iron ore

(FeCO3)

Processes involved in Metallurgy

The following steps are involved in extraction of metals from the ore:-

1. Concentration of Ore or Dressing of the ore.

 Magnetic separation.

Principle: Either the ore or the impurities is magnetic.

Eg: magnetite is concentrated by this method

  Froth flotation process.

Principle: The ore particles get wet by oil while the impurities get wet by
water.

The impure ore is added water in a large container and pine oil or
eucalyptus oil is added to it. Compressed air is passed into the mixture.
Froth is produced. The ore particles rise with the froth. The impurities
get wet by water, become heavy and settle down. The froth is skimmed
off and collected into another container.

This process is used only for sulphide ores

 Hydrolytic method or gravity separation

Principle: The ore and the impurities differ in density.

The impure ore is taken on a sloping table called Wilfley’s table and a
stream of water is passed. Ore particles are generally heavier and settle
down in the grooves of the sloping table. The lighter impurities get
washed away.

 Chemical method

2. Conversion of concentrated ore to oxide.( Roasting and Calcination)

Roasting Calcination

1. Ore is heated below its melting
point in excess of air.
2. Generally done for sulphide ores
1. Ore is heated below its melting
point in the absence or limited
supply of air.
2. Generally done for carbonate
ores

Similarities between calcination and roasting:

 In both the cases, the ore gets converted into its oxide

 Volatile impurities, water vapour etc will escape

  The ore becomes porous

3. Reduction of Oxide to the metal.

 Electrolysis ( K, Na, Ca, Mg, Al)

Compounds of highly reactive metals cannot be reduced by using reducing

agents. They are electrolysed in their molten state to obtain the metal.

 Using reducing agent ( Zn, Fe, Pb, Cu by using Coke, CO and Hydrogen)

The process is carried out in a blast furnace.

 Thermal Decomposition ( Hg and Ag)

 Refining of impure metal

i. Liquation

Principle: The metal and the impurities differ in their melting point.
The metal has a lower melting point than the impurities.

Eg: lead and tin

ii. Oxidation

Principle: The impurities can be oxidised forming volatile

compounds.

Eg: Iron

iii. Distillation

Principle: The metal and impurities differ in their boiling points.

Eg: Zinc

iv. Electrorefining:

Anode: thick block of impure metal

Cathode: thin strip of pure metal

Electrolyte: salt solution of the metal

 When electricity is passed, the metal from the impure block enters
the electrolyte and an equal amount of pure metal is deposited at the
cathode. Impurities settle down below the anode as anode mud.

Eg: silver, gold

EXTRACTION OF ALUMINIUM

Selection of Ore :- Bauxite ( Al2O3.2H2O)

I Concentration of Ore:-

Baeyer’s Process:-

Concentration of ore is done by chemical method (Bayer’s Process) using Sodium

Hydroxide solution.

In this method ore is converted into sodium aluminate which undergoes

hydrolysis to form aluminium hydroxide.

Al2O3.2H2O + 2 NaOH 2NaAlO2 + 3H2O

NaAlO2 + 2H2O  NaOH + Al (OH) 3

Aluminium hydroxide undergoes decomposition at 1100 OC to form Alumina

2Al (OH) 3  Al2O3 +3 H2O

Note :- Above concentration can be done by Hall’s process by using Sodium

Carbonate.

Al2O3.2H2O + Na2CO3  2NaAlO2 + CO2 +2H2O

2NaAlO2 + 3H2O+ CO2  Na2CO3 + Al (OH) 3

2Al (OH) 3  Al2O3 +3 H2O

III. Reduction of Alumina (Hall Heroult’s process) :- ( Alumina to Aluminium)

 Electrolyte:- Fused Alumina + Cryolite + Fluorspar

 Reasons for the adding other components:- Cryolite enhances the

conductivity of the mixture and fluorspar lowers the fusion point of the
mixture. These two components act as a solvent for alumina.
 Electrodes: - Carbon Electrode

Cathode – Carbon lining

Anode – Carbon rods

During the process the anode has to be replaced from time to time as it gets oxidised.

It reacts with the oxygen liberated at the anode to form carbon dioxide.

C+O2 CO2

(Diagram - refer from the text book)

Electrolytic reactions:-

Al2O3  2Al 3+ +3O2- ( Reversible reaction)

At Cathode 2Al 3+ + 6e-  2 Al

At anode 3O2- - 6e  3O2

Coke is sprinkled on the electrolyte to

 Prevent the burning of the electrolytes at the point at which they emerge
from the electrolyte

 Prevent heat loss by radiation

There is a charge control lamp which glows when the concentration of alumina falls
below a particular level. Fresh alumina can be then added. Hence the process is
continuous.

Refining of Aluminium

Hoope’s process

(Diagram - refer from the text book )

The cell contains 3 immiscible layers:-

i. Upper Layer ( Pure molten aluminium with carbon electrode – acts as cathode)

ii. Middle layer ( Mixture of Cryolite, BaF2, AlF, CaF2 - Electrolyte)

 iii. Lower layer ( Impure molten aluminium along with carbon lining –anode)

Electrolytic reactions:-

At anode Al - 3e-  Al 3+ ( Aluminium enters into the middle layer)

At cathode Al 3+ + 3e-  Al ( From the middle layer discharged to the top layer)

Uses of metals:-

Iron :-

Pig iron (carbon content 2.5 – 5%)

- drain pipes

Wrought iron (carbon content 0.1 – 0.25%)

- Chains, horse shoes, electromagnets

Steel (carbon content 0.1– 1.5%)

- automobiles and ships

Mild steel (carbon content 0.1 – 0.5%)

- Nuts and bolts

Hard Steel (carbon content 0.5 – 1.5%)

- Tools

Aluminium :- (Silvery light metal)

-Utensils, paints, packaging

- Electrical cables

Zinc :- (Greyish white metal)

- Galvanization

- Dry cells

- Alloys
ALLOYS :-

Steel Duralumin Brass Bronze Solder

Fe,Ni,Cr,C Al,Mg,Mn,Cu Cu and Zn Cu,Zn & Sn Pb and Sn

Cutlery, Air Crafts,ships Electric Statues, Welding electrical

and light tools Cell fitting, fuse ( low m.p and
surgical medals and
medals high tensile
instruments coins
strength)