BMC MHSS , TUTICORIN

GRADE-XII

UNIT-1 –METALLURGY

EVALUATION

[Link] is the difference between minerals and ores ?

Minerals Ores
Naturally occuring substance obtained Mineral that contains high percentage
by mining which contains the metal in of metal from which it can be
free state or in the form of compounds extracted conveniently and
like oxides, sulphides etc economically are called ores.
All minerals are not ores All ores are minerals
Ex: Clay–Mineral of aluminium Ex: Bauxite–Ore of aluminium

2. What are the various steps involved in extraction of pure metals from their
ores?

 Concentration of the ore.

 Extraction of the crude metal.
 Refining of the crude metal.

3. What is the role of quick lime in the extraction of Iron from its oxide Fe 2O3?

In the extraction of iron , a basic flux quick lime(CaO) is used which decomposes
to form CaO which reacts with silica gangue present in the iron ore is acidic in
nature to form calcium silicate (slag).

CaCO3 CaO+CO2

CaO(s) +SiO2 (s) CaSiO3(s)

Flux Gangue slag

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[Link] type of ores can be concentrated by froth floatation
method? Give two examples for such ores.
Sulphide ores can be concentrated by froth floatation method.
E.x: Galena (PbS), Zinc blende (ZnS)

5. Describe a method for refining nickel.

 Impure nickel is heated in a stream of carbon monoxide at around 350K.
Nickel reacts with CO to form a highly volatile nickel tetra carbonyl. The
solid impurities are left behind.
Ni(s)+4CO(g) NiCO4(g)
 On heating nickel tetracarbonyl around 460K,the complex decomposes
to give pure nickel.
Ni(CO)4(g) Ni(s)+4CO(g)

6. Explain zone refining process with an example.

 The principle used in this process is fractional crystallisation.
 In this process the impure metal is taken in the form of a rod. One end
of the rod is heated using a mobile induction heater which results in
melting the metal on that portion of the rod.
 When the heater is slowly moved to the other end the pure metal
crystallises while impurities will move on to the adjacent molten zone
formed due to the movement of the heater.
 As the heater moves further away,the molten zone containing
impurities also moves along with it.
 This process is repeated several times by moving the heater in the
same direction again and again to achieve the desired purity level.
 This process is carried out in an inert gas atmosphere to prevent
the oxidation of metals.
 Germanium, Silicon and gallium which are used as semiconductor are
refined by this process.

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7. A) Predict the conditions under which

i) Aluminium might be expected to reduce magnesia.

ii) Magnesium could reduce alumina.
B) Is It possible to reduce 𝐅𝐞𝟐𝐎𝟑by coke at a temperature around 1200K

A.i) Ellingham diagram for the formation of Al2O3 and MgO intersects around
1600K. Above this temperature line of ∆G°(𝑀𝑔 ,𝑀𝑔𝑂) lies above the line of
∆G°(𝐴𝑙 ,𝐴𝑙2𝑂3) , Hence we can use aluminium to reduce magnesia above 1600K.

1623K

3MgO+2Al Al2O3+3Mg

ii) 1.4Al+3O2→2Al2O3
2. 2Mg+ O2→2MgO
At the point of intersection of the Al2O3 and MgO curves in Ellingham diagram,
∆G° Becomes zero for the reaction
2Al2O3+2Mg→2MgO+4Al
Below that point magnesium can reduce alumina.

B. In Ellingham diagram above 1000K carbon line lies below the formation of
Fe2O3. Hence it is possible to reduce Fe2O3 by coke at a temperature around
1200K.

8. Give the uses of zinc.

 Metallic zinc is used in galvanization to protect iron and steel structures
from rusting and corrosion.
 It is used to produce die-castings in the automobile, electrical
and hardware industries.
 Zinc oxide is used in the manufacture of paints, rubber, cosmetics,
pharmaceuticals, plastics, inks, batteries, textiles and electrical
equipment.
 Zinc sulphide is used in making luminous paints, fluorescent lights and
x-ray screens.
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  Brass an alloy of zinc which is highly resistant to corrosion is used in water
valves and communication equipment.

[Link] the electrometallurgy of aluminium.( Hall - Heroult Process)

Cathode:Iron tank lined with carbon

Anode: Carbon blocks

Electrolyte: 20% solution of alumina obtained from bauxite + MoltenCryolite+

10% calcium chloride (lowers the melting point of the mixture)
Temperature: Above 1270K

Ionisation of Alumina :Al2O3 2Al3++3O2−

Reaction at cathode :2Al3+(𝑚𝑒𝑙𝑡)+3𝑒− 𝐴𝑙

Reaction at anode : 6𝑂2− (𝑚𝑒𝑙𝑡) 3𝑂2+12𝑒−

Since carbon acts as anode the following reaction also takes

place on it.
C(s) + O2- (melt) CO + 2e -
C(s)+2O2-(melt) CO2 +4e -
During electrolysis anodes are slowly consumed due to the above two
[Link] aluminium is formed at the cathode and settles at the bottom.
Net electrolysis reaction is
4𝐴𝑙3+(𝑚𝑒𝑙𝑡)+6𝑂2−(𝑚𝑒𝑙𝑡) +3 C (S) 4𝐴𝑙(𝑙)+3𝐶𝑂2(𝑔)

[Link] the following terms with suitable examples.i)Gangue ii) Slag

i)Gangue

The non metallic impurities, rocky materials and siliceous matter present in
the ores are called gangue.

E.x:SiO2 is the gangue present in the iron ore Fe2O3.

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ii)Slag
Slag is a fusible chemical substance formed by the reaction of gangue
with a flux. In the extraction of iron, a basic flux lime stone is used
which decomposes to form CaO which reacts with silica gangue
present in the iron ore is acidic in nature to form calcium silicate
(slag)
CaCO3 CaO+CO2
CaO(s) +SiO2 (s) CaSiO3(s)
Flux Gangue slag

[Link] the basic requirement for vapour phase refining.

 The metal should form a volatile compound, when treated with a suitable
reagent
 Then the volatile compound should decomposed to give the pure metal.

[Link] the role of the following in the process mentioned.

i) Silica in the extraction of copper.

ii) Cryolite in the extraction of aluminium.
iii) Iodine in the refining of Zirconium.
iv) Sodium cyanide in froth floatation.
i) In the extraction of copper, silica acts as an acidic flux to remove FeO as
slag FeSiO3.
FeO + SiO2(s) FeSiO3
Flux Slag
ii) Cryolite serves as an added impurity and lowers the melting point of the
Al2O3.
iii) First Iodine forms a Volatile tetra iodide with impure metal, which
decomposes to give pure metal. Impure zirconium metal is heated in an
evacuated vessel with iodine to form the volatile zirconium tetra iodide (ZrI 4).
The impurities are left behind, as they do not react with iodine.

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 iv) Sodium cyanide acts as a depressing agent in froth floatation process.
When a sulphide ore of a metal of interest contains other metal sulphides the
depressing agent sodium cyanide selectively prevent other metal sulphides
from coming to the froth.

[Link] the principle of electrolytic refining with an example.

Crude metal like silver is refined by electrolysis carried out in an electrolytic cell.
Electro refining of silver
1) Cathode:Pure silver
2) Anode:Impure silver rods.
3) Electrolyte:Acidified aqueous solution of silver nitrate.
4) On passing current the following reactions will take place.
5) Reaction at anode:Ag (s) Ag+(aq)+1e−
6) Reaction at cathode:Ag+(aq)+1e− Ag
7) During electrolysis, at the anode the silver atoms lose electrons and
enter the solution. The positively charged silver cations migrate towards
the cathode and get discharged by gaining electrons and deposited on
the cathode.
8) Less electropositive impurities in the anode settle down as anode mud.

[Link] selection of reducing agent depends on the thermodynamic

factor: Explain with an example.
 A suitable reducing agent is selected based on the thermodynamic
considerations.
 For a spontaneous reaction ∆G should be negative.
 Thermodynamically,the reduction of metal oxide with a given
reducing agent can occur if ∆G for the coupled reaction is negative.
 Hence the reducing agent is selected in such away that it provides a large
negative ∆G value for the coupled reaction.
 Ellingham diagram is used to predict thermodynamic feasibility of
reduction of oxides of one metal by another metal.

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 For example
 Above 1623 K, Al has more negative ∆Govalue than Mg
 Hence Al is used to reduce magnesia
 Below 1623K, Mg more negative ∆Go value than Al
 Hence Mg is used to reduce Al

[Link] the limitations of Ellingham diagram.

 Ellingham diagram is constructed based only on thermodynamic
considerations.
 It gives information about the thermodynamic feasibility of a
reaction.
 It does not tell anything about the rate of the reaction.
 It does not give any idea about the possibility of other reactions
that might be taking place.
 The interpretation of ∆G is based on the assumption
that the reactants are in equilibrium with the product
which is not always true.

[Link] a short note on electro chemical principles of metallurgy.

 Reduction of oxides of active metals such as
sodium,potassium [Link] carbon is thermodynamically not
feasible.
 Such metals are extracted from their ores by using electrochemical
methods.
 In this method the metals are taken in fused form or in solution
form.
 The metal ion present can be reduced by treating the solution
with suitable reducing agent or by electrolysis.
 Gibbs free energy change for the electrolysis is
∆G°=−nFE°
n=number of electrons involved in the reduction
F=Faraday=96500 coulombs

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 𝐄°=electrode potential of the redox couple.
 If E° is positive, ∆G° is negative and the reduction is spontaneous.
 Hence a redox reaction is planned in such a way that the
e.m.f of the net redox reaction is positive.
 A more reactive metal displaces a less reactive metal from its
salt [Link] is more reactive than copper and displaces
copper from its salt solution.
Cu(s) + 2Ag+(s) Cu2+(aq)+ 2Ag(s)
Cu2+(aq) +Zn(s) Cu(s) +Zn2+(aq)

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