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DONE BY : G ADITHYA NATARAJ 10 A1

MAJOR STEPS IN EXTRACTION OF METAL


ORE CONCENTRATION
METALS COLLECTED

REDUCTION TO CRUDE METAL

ORE IS PURIFIED AND CONCENTRATED, UNWANTED ROCKS REMOVED

METAL OXIDES TO BE REDUCED TO METALS, RESULTING IN A MIXTURE OF


TO OBTAIN A SPECIFIC METAL, PURIFY AND REMOVE UNWANTED METAL
IMPURITIES

REFINING TO OBTAIN PURE METAL

the extraction of metals


Method of extraction depends on the position of the metal in the reactivity series. extraction of metal involves:
o

getting rid of the unwanted rock to obtain concentrated form of the mineral obtaining pure metal from the mineral by chemical reactions

the extraction of metals


Metals at the top of the reactivity series are very reactive: bonds in their compounds are very strong must be extracted by decomposing their compounds with electricity in an expensive process called electrolysis aluminium is extracted from aluminium oxide by passing an electric current through it

2Al2O3

4Al + 3O2

WAYS OF EXTRACTION
Extraction by electrolysis of molten Al2O3 dissolved in cryolite

POTASSIUM SODIUM CALCIUM MAGNESIUM ALUMINIUM ZINC IRON TIN LEAD COPPER MERCURY SILVER GOLD PLATINUM

K NA CA
MG AL ZN FE SN PB

Extracted by electrolysis of molten chlorides

Extraction by reduction of oxides using carbon Roasting ore by heating alone

CU HG
AG AU PT

EXTRACTION OF IRON

RAW MATERIALS OF EXTRACTION OF IRON


IRON ORE COKE
EG HAEMATITE ORE [IRON(III) OXIDE, FE2O3]

CARBON, C
FOR THE O2 IN IT CALCIUM CARBONATE, CACO3

HOT AIR

LIMESTONE

STAGE 1 PRODUCTION OF CARBON DIOXIDE


THE COKE IS IGNITED AT THE BASE AND HOT AIR BLOWN IN TO
BURN THE COKE (CARBON) TO FORM CARBON DIOXIDE

C(S) + O2(G) CO2(G)

THE LIMESTONE IS DECOMPOSED BY HEAT TO PRODUCE


CARBON DIOXIDE & QUICKLIME

CACO3(S) CAO(S) + CO2(G)

STAGE 2 PRODUCTION OF CARBON MONOXIDE


AT HIGH TEMPERATURE, THE CARBON DIOXIDE FORMED
REACTS WITH MORE COKE (CARBON) TO FORM CARBON MONOXIDE

CO2(G) + C(S) 2CO(G)

STAGE 3 REDUCTION OF HAEMATITE


THE CARBON MONOXIDE REMOVES THE OXYGEN FROM THE

THIS FREES THE IRON, WHICH IS MOLTEN AT THE HIGH


FE2O3(S) + 3CO(G) 2FE(L) + 3CO2(G) OTHER POSSIBLE ORE REDUCTION REACTIONS ARE ...
FE2O3(S) + 3C(S) 2FE(L) + 3CO(G) 2FE2O3 (S) + 3C(S) 4FE(L) + 3CO2 (G)
BLAST FURNACE TEMPERATURE, AND FLOWS DOWN TO THE BASE OF THE BLAST FURNACE.

IRON OXIDE ORE.

STAGE 3 REDUCTION OF HAEMATITE

WASTE GASES ESCAPE THROUGH THE TOP OF THE FURNACE EG. CARBON MONOXIDE, CARBON DIOXIDE, NITROGEN

STAGE 4 REMOVAL OF IMPURITIES


THE ORIGINAL ORE CONTAINS SILICA (SIO2, SILICON
DIOXIDE). THESE REACT WITH LIMESTONE TO FORM A MOLTEN SLAG OF E.G. CALCIUM SILICATE IN 2 STAGES

THE MOLTEN SLAG FORMS A LAYER ABOVE THE MORE


DENSE MOLTEN IRON AND CAN BE SEPARATELY, AND REGULARLY, DRAINED AWAY. THE IRON IS COOLED AND CAST INTO PIG IRON INGOTS / TRANSFERRED DIRECTLY TO A STEEL PRODUCING FURNACE

CACO3 CAO + CO2 CAO + SIO2 CASIO3

SLAG CAN BE USED FOR ROAD SURFACING

WHY STEEL?
STEEL IS IRON THAT HAS MOST OF THE IMPURITIES REMOVED.
STEEL ALSO HAS A CONSISTENT CONCENTRATION OF CARBON THROUGHOUT (0.5 PERCENT TO 1.5 PERCENT)

IMPURITIES LIKE SILICA, PHOSPHOROUS AND SULPHUR


STRENGTH

WEAKEN STEEL TREMENDOUSLY, SO THEY MUST BE ELIMINATED

THE ADVANTAGE OF STEEL OVER IRON IS GREATLY IMPROVED

PIG IRON TO STEEL USING BASIC OXYGEN FURNACE PEAR-SHAPED FURNACE, LINED WITH REFRACTORY BRICKS, THAT REFINES MOLTEN IRON FROM THE BLAST FURNACE
AND SCRAP INTO STEEL SCRAP IS DUMPED INTO THE FURNACE VESSEL FOLLOWED BY THE HOT METAL FROM THE BLAST FURNACE. A HIGH-PRESSURE STREAM OF OXYGEN IS BLOWN INTO IT TO CAUSE CHEMICAL REACTIONS THAT SEPARATE IMPURITIES AS FUMES OR SLAG ONCE REFINED, THE LIQUID STEEL AND SLAG ARE POURED INTO SEPARATE CONTAINERS

TYPES OF STEEL
Steel Mild carbon steel High carbon steel Stainless steel alloy Percentage of carbon Up to 0.25% 0.45% - 1.50% Little carbon, with chromium & nickel

PROPERTIES OF STEEL

CAN BE CHANGED BY THE USE OF CONTROLLED ADDITIVES EG. CARBON, CHROMIUM, NICKEL, MANGANESE, SILICON ETC

Steel Mild carbon steel strong, hard & malleable High carbon steel strong but brittle Stainless steel does not rust

USES OF STEEL

Uses Make steel parts in car bodies , machineries Make knives, hammer, cutting tools Pipes & tanks in chemical plants, making cutlery, surgical instruments

ALLOY

MIXTURE OF A METAL WITH OTHER ELEMENTS ELEMENT IN THE LARGEST PROPORTION IS THE BASE METAL ELEMENTS IN SMALLER PROPORTIONS ARE THE ALLOYING ELEMENTS

METALS
SOFT LOW RESISTANCE TO CORROSION HIGH M.P EASY TO SHAPE

ALLOYS
HAVE DIFFERENT PHYSICAL PROPERTIES COMPARED TO THEIR CONSTITUENT
ELEMENTS

PRODUCE MAINLY FOR:

IMPROVING STRENGTH AND HARDNESS IMPROVING RESISTANCE TOWARDS CORROSION IMPROVING APPEARANCE OF METAL LOWER M.P OF METAL

EXTRACTION OF ALUMINIUM FROM BAUXITE

RAW MATERIALS
AL2O3.2H2O

BAUXITE: ORE CONTAINING HYDRATED ALUMINIUM OXIDE


M.P: ~2000C

MOLTEN CRYOLITE AKA SODIUM ALUMINIUM FLUORIDE NA3ALF6


USED TO LOWER M.P TO ~900C

CARBON ELECTRODES

EXTRACTION OF ALUMINIUM

CRYOLITE IS ADDED TO LOWER THE MELTING POINT & TO DISSOLVE THE ORE &
BAUXITE ORE OF ALUMINIUM OXIDE IS CONTINUOUSLY ADDED

WHEN P.D IS APPLIED,

AL3+ IS ATTRACTED TO THE NEGATIVE CATHODE O2- IS ATTRACTED TO THE POSITIVE ANODE

EXTRACTION OF ALUMINIUM AT THE CATHODE,


ALUMINIUM, WHICH IS TAPPED OFF

AL3+ GAINS 3 ELECTRONS FROM THE CATHODE TO FORM MOLTEN


AL3+(L) + 3E- AL (L)

AT THE ANODE,

O2- LOSES 2 ELECTRONS TO THE ANODE TO FORM OXYGEN 2O2-(L) O2(G) + 4E OXYGEN RELEASED ATTACKS CARBON ANODE, TO FORM CARBON
MONOXIDE/DIOXIDE. CARBON ANODE DISSOLVED. NEEDS TO BE REPLACED REGULARLY

CONDITIONS FOR CORROSION OF IRON

PRESENCE OF OXYGEN PRESENCE OF WATER PRESENCE OF SODIUM

CHLORIDE/ACIDIC POLLUTANTS SPEED UP RUSTING

4Fe(s) + 3O2(g) +
RUSTING IS AN EXOTHERMIC REDOX xH2O(l) REACTION2 WHERE IRON IS OXIDIZED TO FORM HYDRATED IRON(III) OXIDE

2Fe2O3.xH2O (s)

PREVENTION OF RUSTING
USE OF PROTECTIVE LAYER PAINTING USED IN CARS, SHIPS, BRIDGES GREASING TOOLS & MACHINE PARTS ZINC PLATING(GALVANISING) ZINC ROOFS TIN PLATING FOOD CANS CREATES BARRIER AROUND THE METAL PREVENTING CONTACT WITH
OXYGEN AND WATER

SACRIFICIAL PROTECTION
MORE REACTIVE METAL, EG, MAGNESIUM OR ZINC IS ATTACHED TO IRON OR
STEEL

PROTECTS BY SACRIFICING ITSELF, CORRODES FIRST SINCE IT IS MORE


REACTIVE

IRON WILL NOT RUST IN THE PRESENCE OF A MORE REACTIVE METAL USED IN UNDERGROUND PIPES, SHIPS, STEEL PIERS

ALLOYING
ADDITION OF NICKEL AND CHROMIUM TO IRON CHROMIUM (III) OXIDE CR2O3 ON THE SURFACE PROTECTS IRON FROM
CORROSION

USED IN CUTLERY, SURGICAL INSTRUMENTS, PIPES & TANKS IN CHEMICAL


PLANTS

FINITE RESOURCE
METAL ORES FINITE RESOURCE, WILL BE USED UP NEED TO RECYCLE METALS SAVE RESOURCES AND SOLVES LITTER DISPOSAL SAVES ENERGY SAVES COSTS

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