Metal and Alloys
Refining:
Refining is the process of removing impurities from a metal to make it pure and high-quality.
Following are the Refining of
* Copper * Aluminium * Zinc
Refining of Copper:
Refining of copper is done by passing electricity through a solution of copper. Impure copper
dissolves from the anode and pure copper deposits on the cathode. The impurities fall to the
bottom as anode mud, leaving copper pure.
Construction:
Electrolytic Tank
An electrolytic tank is a plastic or cement container. It is filled with copper sulphate and
dilute sulphuric acid solution. This solution helps electricity pass and allows copper to
dissolve and deposit.
Anode (Impure Copper)
The anode is made of thick plates of impure copper. These plates are connected to the
positive terminal of the power supply. They slowly dissolve to release copper ions during
refining.
Cathode (Pure Copper)
The cathode is a thin sheet of pure copper. It is connected to the negative terminal of the
power supply. Pure copper deposits on it, making it thicker and cleaner.
Working:
Anode Reaction
When current flows, impure copper from the anode dissolves. It forms copper ions (Cu²⁺)
and releases electrons.
Cu(s) → Cu²⁺ + 2e⁻
Cathode Reaction
Copper ions in the solution move to the cathode. They gain electrons and form pure copper
metal.
Cu²⁺ + 2e⁻ → Cu(s)
Anode Mud Formation
The impurities do not dissolve in the solution. They fall to the bottom of the tank. This
collected material is called anode mud.
Result: The Obtain copper is 100% pure and can used in industry.
Visualization
Refining of Aluminum:
Aluminium is refined by electrolytic refining using molten aluminium oxide. Impurities
remain behind, and pure aluminium collects at the cathode.
The Aluminium can be refined into two ways both are following:
* Hall–Heroult Process
* Hoop’s process
Hall–Heroult Process
Construction
Electrolytic Cell
A steel tank lined with carbon acts as the cathode. It holds molten aluminium oxide mixed
with cryolite (AlF₃). Cryolite lowers the melting point and improves conductivity. The tank
is insulated to maintain high temperature (~950°C).
Anode (Carbon Rods)
Thick carbon rods are dipped into the molten mixture. These rods act as anodes (positive
electrodes). They react with oxygen ions from aluminium oxide. This allows the continuous
flow of electric current.
Cathode (Carbon Lining)
The carbon lining at the bottom acts as the cathode (negative electrode). Molten aluminium
collects here after gaining electrons. It is denser than the electrolyte, so it stays at the bottom.
Pure aluminium can be tapped off without impurities.
Working
Oxide Dissolves in Electrolyte
Aluminium oxide dissolves in molten cryolite. This allows ions to move freely under electric
current. Al³⁺ ions move toward the cathode, O²⁻ ions move to the anode. Impurities stay in
the electrolyte or float as slag.
Cathode Reaction
Al³⁺ ions gain electrons at the carbon cathode. They are reduced to form molten pure
aluminium.
Equation:
Al3 + e- →Al(l)
This aluminium collects at the bottom of the cell.
Anode Reaction
O²⁻ ions from aluminium oxide move to the carbon anode. They lose electrons and form
oxygen gas.
Equation:
2O2 −→O2 +4e-
Some oxygen reacts with the carbon anode to form CO₂ gas.
Hoop’s process
Hoop’s Process is used to produce very pure aluminium (up to 99.99%). It uses three layers
of molten metals/electrolyte instead of a single layer. It is mainly applied when extremely
high-purity aluminium is required.
Construction
Three-Layer Cell
The cell contains three separate molten layers that do not mix.
Top layer: pure aluminium, Middle: molten electrolyte, Bottom: impure aluminium.
The layers stay separate because of density differences. This arrangement ensures efficient
removal of impurities.
Anode (Outer Iron Tank)
The iron tank acts as the anode (positive electrode). It attracts oxide ions from the electrolyte.
Impurities rise into the middle layer and are removed. The current flows continuously,
allowing electrolysis to occur.
Cathode (Top Pure Aluminium Layer)
The top molten aluminium layer acts as the cathode (negative electrode). Aluminium ions
from the electrolyte move upward to this layer. They gain electrons and deposit as highly
pure aluminium. The pure aluminium layer can be tapped off without disturbing other layers.
Working:
Oxide Dissolves in Middle Layer
Impure aluminium oxide is dissolved in the middle molten electrolyte. Aluminium ions
move toward the top cathode layer. Impurities like iron and silicon stay in the middle or
bottom layers. The electrolyte allows free movement of ions for refining.
Cathode Reaction
Aluminium ions reach the top layer and gain electrons. They are reduced to form molten
pure aluminium.
Equation:
Al3 + e- →Al(l)
This produces extremely high-purity aluminium at the cathode.
Separation of Pure Aluminium
Molten aluminium remains in the top layer because it is lighter than the other layers. It is
periodically removed through a tapping outlet. The middle layer retains the electrolyte with
dissolved impurities. The process can be repeated to maintain constant purity.
Refining Of Zinc:
Zinc is refined to remove impurities such as iron, lead, and cadmium. The industrial method
mainly used is distillation after smelting. Zinc ores like zinc blende (ZnS) are first processed
to zinc oxide. Pure zinc is collected for industrial and commercial use.
Construction
Roasting Furnace
Zinc sulphide (ZnS) ore is heated in a furnace with air. Sulphur in the ore reacts with oxygen
to form sulphur dioxide gas. This converts ZnS into zinc oxide (ZnO). The roasted ore is
ready for smelting.
Smelting Furnace
Zinc oxide is mixed with carbon (coke) and heated at high temperature (~1200°C). The
carbon reduces zinc oxide to zinc vapor. Impurities like iron, lead, and cadmium do not
vaporize. Zinc vapor rises for collection while residue remains behind.
Condensation Chamber
Zinc vapor enters a condensation chamber. It is cooled down to form molten or solid pure
zinc. Impurities either remain in the furnace or escape as gas. The pure zinc is then collected
and cast into required forms.
Working
Roasting
Zinc sulphide is heated in air in a furnace Sulphur reacts with oxygen to form sulphur
dioxide. Zinc sulphide converts into zinc oxide.
Equation:
2 �� � + 3 �2 → 2 �� 0 + 2��2
Smelting / Reduction
Zinc oxide is mixed with carbon and heated at high temperature Carbon reduces ZnO to form
zinc vapor. Impurities like iron and lead remain in the furnace.
Equation:
Zn O + C → (Zinc vapour) + CO
Condensation / Collection
Zinc vapor rises into the condensation chamber. It is cooled to form pure molten or solid zinc.
Impurities either stay in the furnace or are removed as gas. The final product is high-purity
zinc ready for industrial use.