CHEMISTRY

Class – VIII
TOPIC- METALLURGY
 METALLURGY

Minerals: Inorganic compounds which are found in the earth’s crust having
metals in combined state.
Eg: Bauxite and clay are minerals of aluminium.

Ores: The minerals from which profitable extraction of metal can be done.
Eg: Bauxite(Al2O3.2H20), Haematite (Fe2O3)

Gangue: The earthy impurities present in the ore like clay, sand and dust.
 Metal Ore Chemical Formula

Aluminium Bauxite Al2O3.2H20

Iron Magnetite Fe304

Haematite Fe2O3
Copper Copper pyrite CuFeS2
copper glance Cu2S
Cuprite Cu2O
Zinc Zinc Blende ZnS
Calamine ZnCO3
Calcium Marble (limestone) CaCO3

Lead Galena PbS

Mercury Cinnabar HgS

 TYPES OF ORE
• Oxide ores
Bauxite Al2O3 ∙ 2H2O
Haematite Fe2O3
Magnetite Fe3O4
Cuprite Cu2O

• Carbonate Ore
Marble CaCO3
Calamine ZnCO3
Sulphide ores
Cinnabar HgS
Galena PbS
Zinc Blende ZnS
Copper Pyrite CuFeS2
Copper glance Cu2S
Q. All Ores are minerals, but all minerals are
not Ores.
A. .Because only those minerals from which
metals can be extracted are called ores, rest of
the minerals from which metals cannot be
extracted are called minerals only and not ores.
METALLURGY- the steps involved in the extraction of metal from its ore
and refining it is called metallurgy.
STEPS OF METALLURGY-
 STEPS OF METALLURGY
1. Concentration of ores/Enrichment of ores

2. Conversion of ore in to metallic oxide

3. Reduction of metallic oxide to metal

4. Refining of metals
 I. Concentration / Enrichment of Ore
This can be done in the following ways:
A) Hydraulic washing / Gravity separation
Principle: -It is based on difference in densities of ore and gangue. For
example heavier ores like Limestone- CaCO3,Calamine - ZnCO3, Haematite-
Fe2O3.
Procedure: The powdered ore is dropped on a slopping table and a stream of
water is passed through it. The ore being heavier settles down whereas the
impurities being lighter are washed away.
B. MAGNETIC SEPARATION

Principle: Difference in the magnetic properties

of the ore and gangue particles forms the basis of their separation
Magnetic ore of Fe(Fe3O4), Cr etc. are concentrated by the method.

Procedure: The powdered ore is dropped on a conveyer belt moving over two rollers,
out of which one is magnetic. The magnetic ore is collected in one container whereas
non-magnetic gangue are collected in another container.
Q. Why Haematite (Fe2O3 ) although a
magnetic ore ,is still concentrated by hydraulic
washing ?
A. Because Haematite ore contains impurities
like chromium and nickel which are also
magnetic in nature ,so it cannot be concentrated
by magnetic separation. Thus being heavier it is
concentrated by hydraulic washing
C. FROTH FLOATATION

Principle - Difference in the wetting properties of the ore and gangue

particles forms the basis of their separation.
Lighter sulphide ores ex. Cinnabar, copper pyrite are concentrated using
this method.
Procedure: - The ore is mixed with water and pine oil and compressed
air is passed. Froth containing ore is formed as a top layer and is
collected in another container which on washing with water gives ore
back. The impurities being heavier settle down.
 II. CONVERTING CONCENTRATED ORE TO METAL OXIDE

It can be done in two ways:

A. Calcination B. Roasting

A. CALCINATION :

• Heating the ore in absence of air.

• Hydrated and Carbonate ores are calcinated.
• Calcination removes moisture and volatile impurities present in the ore.
∆
Al2O3.2H2O՜ Al2O3+2H2O↑(g)
Bauxite
∆
CaCO3՜ CaO+CO2↑(g)
Limestone

∆
ZnCO3՜ ZnO+CO2↑(g)
Calamine
B. ROASTING:

• Heating the ore in presence of air.

• Sulphide ores are roasted.
• Roasting removes moisture and volatile impurities present in the ore.

∆
2PbS + 3O2՜ 2PbO+2SO2↑(g)
Galena

∆
2HgS + 3O2՜ 2HgO+2SO2↑(g)
Cinnabar

∆
2Zn𝑆 + 3𝑂2՜ 2ZnO+2SO2↑(g)
Zinc Blende
 Roasting Calcination

It is the process of heating It is process of heating of

of ore in presence of air. ore in absence of
air.

It is done for Sulphide ores It is done for carbonate

ores

SO2 gas is released. CO2 gas is released.

2HgS + 3O2 Heat 2HgO + 2SO2 CaCO3 Heat CaO + CO2

Q. What happens when(chemical equation)

1) Galena is roasted,
2) Zinc Blende is roasted,
3) Calamine is calcinated,
4) Bauxite is calcinated,
5) Cinnabar is roasted.
1) 2PbS + 3O2 Heat 2PbO + 2SO2

2) 2ZnS +3O2 Heat 2ZnO + 2SO2

3) ZnCO3 Heat ZnO + CO2

4) Al2O3 ∙ 2H2O Heat Al2O3 + 2H2O

5) 2HgS + 3O2 Heat 2HgO + 2SO2

 III. REDUCTION OF METAL OXIDE TO METAL

Reduction of metal oxide to metal is done by using

different reducing agents like heat(Thermal), Al, C, CO
(Chemical), electric current(Electrolytic), etc.

The choice of the reducing agent depends upon the

position of metal in the reactivity series.

Oxides of least reactive metals- Thermal Reduction

Oxides of moderately reactive metals- Chemical
Reduction
Oxides and chlorides of reactive metals- Electrolytic
Reduction
K Highly reactive metals(electrolytic reduction)
Na
Ca 2Al2O3 electricity 4Al + 3O2
Mg
Al
Zn Moderately reactive
Fe Reducing agent – C / CO /Al
Ni (Chemical reduction)
Sn Fe2O3 + 3C Heat 2Fe + 3CO smelting
Pb Fe2O3 + 3CO Heat 2Fe + 3CO2
H
Cu less reactive
Hg
Ag 2HgO Heat 2Hg + O2
Au (Thermal reduction)
Pt Reducing agent – Heat
 THERMAL CHEMICAL ELECTROLYTIC
REDUCTION REDUCTION REDUCTION

It is the process of It is the process of It is the process of

reducing Metallic reducing Metallic reducing metallic
oxide to metal by oxide to metal by oxide to metal by
passing heat. using reducing passing electric
agent like C/ current.
CO/Al.

It is done for the Done for the Done for the oxide
oxides of less oxides of of highly reactive
reactive metal. moderately metals.
reactive metal.
1. Thermal Reduction: Oxides of metals which
are low in reactivity series can be reduced to
metal by heating alone.

∆
2 HgO ՜ 2 Hg + O2
2. Chemical reduction: Oxides of metals which are in the middle of the reactivity
series can be reduced to metals by using suitable reducing agents like carbon,
carbon monoxide, Aluminium, etc.
∆
ZnO + C ՜ Zn + CO
∆
Fe203 + 3 C ՜ 2 Fe + 3 CO

Smelting: It is the process of reduction of metal oxide to metal by heating with

coke. ∆
Fe203 + 3 CO ՜ 2 Fe + 3 CO2
∆
PbO + CO ՜ Pb + CO2
Aluminothermy: It is the process of reduction of metal oxide to metal by heating
with Aluminium to obtain metal in molten form. It is an exothermic reaction.

∆
Fe2O3 (s) + 2 Al (s) ՜ 2 Fe (l) + Al2O3 (s) + Heat
Molten → used to join railway tracks or cracked machine parts.
∆
3 MnO2 (s) + 4 Al (s) ՜ 3 Mn (l) + 2 Al2O3 (s) + Heat

∆
Cr2O3 (s) + 2 Al (s) ՜ 2 Cr (l) + Al2O3 (s) + Heat
3. Electrolytic Reduction : Oxides and chlorides of metals which are high up in the
reactivity series can be reduced to metals by passing electric current

𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐶𝑢𝑟𝑟𝑒𝑛𝑡
2 NaCl 2 Na + Cl2↑

At cathode: 2Na+ + e- →2Na

At anode: 2 Cl- - 2 e- → 2 Cl or Cl2

𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐶𝑢𝑟𝑟𝑒𝑛𝑡
2 Al2O3 4 Al + 3 O2↑

At cathode: 4Al+3 + 12 e- → 4Al

At anode: 6 O-2 - 12 e- → 6O or 3O2
Q. Identify the reducing agent and method for
the following: -
PbO
ZnO
HgO
CuO
Substance Reducing Agent Method

ZnO/PbO C Chemical
reduction

CuO/HgO Heat Thermal

reduction
Q. Why we take molten NaCl and not aqueous
NaCl solution for its electrolytic reduction ?

A. We cannot take aqueous NaCl because in this

case of aqueous NaCl, NaOH is formed.
Q. Coke can reduce Fe2O3 to Fe but not Al2O3 to
Al. Why?

Q. The carbonate and sulphide ores are

converted to their metallic oxide before
reduction. Why?
A. Because iron is moderately reactive metal
so coke can easily break the bond between
iron and oxygen whereas Aluminium is
highly reactive metal, so it is not possible.

A. Because it is easier to reduce metallic

oxide to metal rather ore to metal directly.
What happens when: -

1. Electric Current is passed through molten

sodium chloride.
2. Manganese di oxide is heated with
aluminium.
3. Zinc oxide is heated with carbon monoxide.
4. Cupric oxide is heated.
1. 2NaCl electric current 2Na + Cl2

2. 3MnO2 + 4Al Heat 3Mn + 2Al2O3

3. ZnO + CO Heat Zn + CO2

4. 2CuO Heat 2Cu +O2

Q. Write the reactions taking place at cathode
and anode in the electrolytic reduction of Al2O3 .
 Al2O3 electric current Al+3 + O-2

At cathode (reduction) Al+3 + 3e- Al

At anode (oxidation) O-2 – 2e- O O + O O2

 IV REFINING OF METAL
LIQUATION: - principle – based on difference in
melting point of metal and impurities. For
example lead (pb), tin (sn).
Distillation: - principle – based on difference in
boiling point of metal and impurities. For example
zn and hg.
Oxidative refining: - principle – based on
difference in oxidising property of metal and
impurities. For example fe.
Electrolytic refining: - principle – based on
difference in chemical properties of metal and
impurities. For example. Cu
Procedure: - We take impure copper [Anode],
pure copper [cathode] and copper sulphate
[electrolyte] and arrange them according to
the figure. When electric current is passed
chemical reaction takes place and pure
Copper is collected at cathode.

Anode mud: - These are the impurities which

get collected near anode in the refining of the
metal, for example. In the refining of copper
traces of Au and Ag are collected as anode
mud.
 Reactive Impurities: Metals which are
more reactive than Copper (Fe, Zn) will
oxidize to Fe+2 and Zn+2 ions and will be
left in the solution.
Impurities
present are
of two types Less reactive Impurities: Impurities of
metals which are less reactive than
Copper (Au, Ag) will get collected below
the anode as anode mud.
Q. Write the steps of metallurgy involved in
converting ZnS Zn.
A. Concentration of ore – Froth Floatation
Conversion of ore to metallic
oxide roasting
2ZnS +3O2 Heat 2ZnO + 2SO2
Reduction of metallic oxide to metal
Chemical reduction
ZnO + CO Heat Zn + CO2
Refining - Distillation
Q. Write the steps of metallurgy involved in
converting ZnCO3 Zn
A. Concentration of ore – Hydraulic Washing
Conversion of ore to metal - calcination
ZnCO3 Heat ZnO + CO2
Reduction of Metallic oxide to metal
Chemical reduction
ZnO + C Heat Zn + CO
Refining - Distillation
ALLOY: - It is a homogenous mixture of two or
more metals or a metal and a non-metal

NEED FOR MAKING ALLOY: -

To increase hardness
To prevent corrosion
 ALLOY COMPOSITION USES
1. Steel Fe + C For building
purpose

2. Stainless Fe + Cr + Ni Surgical
Steel instruments
Watches
Utensils
Equipments

3. Brass Cu + Zn Utensils
Decorative Items
Sculptors
 ALLOY COMPOSITION USES
4. Bronze Cu + Sn Medals
statues

5. Duralumin Al + Mg + Mn + Cu Aircraft bodies,

Pressure
cookers

6. Magnelium Al + Mg Scientific
instruments,
Beam balance
 ALLOY COMPOSITION USES

7. Solder Pb + Sn For joining

electric circuits,
to make fuse
wires

8. Alloy of Au + Cu / Ag Medals,
gold Jewellery
Q. What is meant by 22 carat gold?
Ans. It means it’s an alloy containing 22 part
gold and 2 part Cu or Ag.