Metallurgy Notes

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Chapter – 6
METALLURGY
Metal: Metal is an element which ionizes by losing one or more electrons.
 Metals have 1,2 or 3 electrons in their valence shell.
 They lose electrons and form positive ions (cations) hence they form electrovalent
compounds.
Na – e- Na+
Mg – 2e- Mg2+
Al – 3e- Al3+

Chemical properties:
Metals Non-metals
1. Have 1, 2 or 3 valence electrons. 1. Have 4, 5, 6 or 7 valence electrons.
2. They form cations by losing electron/s. 2. Form anions by gaining electron/s.
And Reducing agents (donate electrons) And Oxidizing agents (accept electrons).
3. Electropositive elements. 3. Electronegative elements.
4. During electrolysis cations gain 4. Anions lose electrons (get oxidized) and
electrons (get reduced) and are are discharged.
discharged.
5. Active metals react with dil. acids to 5. Non-metals do not give Hydrogen gas
liberate Hydrogen gas. with dil. acids.
Reason: active metal can transfer Reason: Electron transfer does not take
electrons to the Hydrogen ions of acids place from the non-metals to the
and neutralize them to atoms. Hydrogen ion of the acid.
6. Metal oxides are basic in nature. 6. Non-metallic oxides are acidic in nature
(Al2O3, ZnO and PbO are amphoteric in and form acids when dissolved in water.
nature). (CO, NO,N2O, H2O are neutral oxides)
7. Metal chlorides are solids and non- 7. Non-metallic chlorides are volatile
volatile. liquids.
Electrovalent compounds. Covalent compounds

Mineral: Naturally occurring compounds of metals along with the earthly impurities.
Ore: The mineral from which metals are extracted easily and profitably.
Metallurgy: The process in which metals are extracted from their minerals.
Matrix (or) Gangue: The impurities that associated with an ore.

Metallurgy involves the following steps:


Step -I - Concentration of Ore-Removal of impurities.
Step - II - Conversion of ore to metal oxide.
Step - III - Reduction of the metal oxide to the metal.
Step - IV - Refining impure metal to pure metal.

Step – I Concentration of the Ore:


The matrix is removed from the ore using the following processes.
1. Magnetic separation:
2. Froth flotation method:
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3. Hydrolytic method:
4. Chemical method:

Step – II Concentrated ore to metal oxide


The concentrated ore is converted to metal oxides by the following processes.
1. Calcination: Heating the concentrated ore in presence of limited air or in the absence
of air.
2. Roasting: Heating the concentrated ore in presence of air (Oxygen).
This step is not required where the ore is a metal oxide.

Step – III Reduction of metal oxide to metal.


In this step the metal oxides are reduced based on their position in the activity series.
 The metals from Na to Al : their oxides are reduced by electrolysis.
 The metals from Zn to Cu : their oxides are reduced using reducing agents.
 Hg and Ag are obtained by the thermal decomposition of their oxides.

Step – IV Refining of impure metal:


The refining of impure metal is done in the following methods:
1. Distillation refining: Zinc, Mercury
2. Liquation refining: Lead, Tin
3. Oxidation refining: Impurities like S, C and P are removed from Iron
4. Electro-refining: Impure metals are purified by electrolysis by taking a block of
impure metal as anode. Copper, Al, Pb etc.

Extraction of Aluminium from Bauxite ore:


Ore : Bauxite – Al2O3.2H2O – Hydrated Aluminium oxide

Step I: Concentration of ore


The matrix is removed by chemical method.
Chemical used : Conc. Sodium hydroxide solution
Process name: Baeyer’s process

 Al2O3.2H2O + 2NaOH 2NaAlO2 + 3H2O


The amphoteric nature of Aluminium oxides makes it react with NaOH where as other
impurities like Fe2O3 and SiO2 do not react and will be separated out.

 NaAlO2 + 2H2O NaOH + Al(OH)3


Al(OH)3 crystals are added to the dil. NaAlO2 solution to further precipitate out Al(OH)3
crystals this process is called seeding.

 2Al(OH)3 Al2O3 + 3H2O


Alumina
Step II : This step is not necessary as the pure ore is an oxide.
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Step III : Reduction of pure Alumina to Aluminium.


Aluminium oxide (Alumina) is not reduced by reducing agents because it is highly
stable hence Alumina is reduced by electrolysis in Hall Heroult’s process.

Hall Heroult’s process

Electrolyte : Fused mixture of Alumina (Al2O3) , Cryolite (Na3AlF6) and


Fluorspar (CaF2) in the ratio 1:3:1.
Reason: Cryolite lowers the fusion point of Alumina (20500C to 9500C)and enhances the
conductivity of the electrolyte.
Electrolytic cell : Steel tank with Carbon lining acts as cathode.
Electrodes : Anode – A series of Graphite electrodes
Cathode – The electrolytic cell with Carbon lining
Graphite rods connected in a series is taken as anode instead of one Graphite rod because the
Oxygen released at anode will oxidize them to CO and CO2.
Precaution:
Coke powder is sprinkled on the surface of fused electrolyte.
Reason: It prevents the oxidation of anode by the atmospheric Oxygen and heat loss by
radiation.

Electrolytic reaction involves the following steps:


Na3AlF6 3Na+ + Al3+ + 6F –

CaF2 Ca2+ + 2F –

Al2O3 2Al3+ + 3O2 –

at cathode : 2Al3+ + 6e – 2Al product: pure Aluminium metal


at anode : 6O2 – - 12e – 3O2 product: Oxygen gas (CO and CO2)
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Step IV is not necessary because the Aluminium metal obtained in Hall Heroult’s process is
99.5% pure. (Further purification can be done by Hoope’s process.)

Uses of Aluminium:
Use of Aluminium Reason for use
1. Household utensils Light, corrosion resistance, good conductor
of heat and unaffected by food acids.
2. Aluminium + Linseed oil used in paints Aluminium layer prevents corrosion of Iron
3. Thin Aluminium foil is used in Aluminium is has bright appearance and
packaging corrosion resistant.
4. Aluminium wires are used as electric Al is a good conductor of electricity.
cables
5. In alloys like Duralumin and Magnalium Light , has structural strength and corrosion
resistant.
6. Thermite welding: The mixture of Al is a strong reducing agent.
Aluminium and Fe2O3 is used to fill the 2Al + Fe2O3 Al2O3 + 2Fe + (energy)
gaps in girder

Alloy: An alloy is a solid homogeneous mixture of two or more metals.


Alloy – composition Use of the alloy
1. Brass – Copper + Zinc Electric fittings
2. Bronze – Copper + Tin + Zinc statues, medals, coins
3. Duralumin – Al + Mg + Mn + Cu Aircrafts, light tools etc
4. Stainless steel – Fe + Ni + Cr + C Cutlery, utensils etc
5. Solder – Pb + Sn Electric fuse, Soldering
Amalgam : It is an alloy in which one of the constituent metals is Mercury.
e.g - Na/Hg, Zn/Hg

Metal – its ore Formula


Aluminium – Bauxite Al2O3.2H2O
Aluminium - Cryolite Na3AlF6

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