EXTRACTION OF METALS Form 3.

Properties of metals

1 Metals are good thermal and electrical conductors because they

have delocalized electrons which are mobile.

2 Metals are malleable and ductile because their ions can slide over
each other when a force is applied.

3 Metals have high melting points and boiling points because of

strong metallic bonding.

Uses of metals

(a) aluminium in the manufacture of aircraft because of its low

density

(b) aluminium in the manufacture of overhead electrical cables

because of its low density and good electrical conductivity

(c) aluminium in food containers because of its resistance to

corrosion

(d) copper in electrical wiring because of its good electrical

conductivity and ductility

ORE – an ore is a rock or mineral from which a metal can be

extracted by mining e.g. bauxite, haematite, malachite,

common chemical name metal method of extraction

ore extracted
haematite iron(III)oxide Fe2O3 iron reduction
malachite copper copper electrolysis
 carbonate(CuCO3)
bauxite aluminium oxide aluminium electrolysis
(Al2O3)
galena lead sulphide PbS lead reduction
zinc blende zinc sulphide ZnS zinc reduction
brine sodium chloride NaCl sodium electrolysis

INDUSTRIAL PROCESSES OF EXTRACTING METALS

1 Metals on top of the reactivity series are extracted by electrolysis,

e.g. K, Na, Mg, Ca, Al. They are very reactive and are found combined
with other elements.

2 Metals in the middle of the reactivity series e.g. Fe, Zn, Pb, Cu are
extracted by reduction of the ore (Heating the ore with
carbon/coke). Reduction is the removal of oxygen or sulfur from a
compound.
3 Metals at the bottom of the reactivity series are found free in the
earth crust e.g. gold, silver, platinum.

N.B. Metals such as copper, nickel are purified by electrolysis.

Extraction of iron in the blast furnace

The blast furnace is a large steel furnace up to 30m tall. It is
surrounded on the outside with an insulating layer of heat proof
bricks or a refractory lining of magnesium oxide (MgO). The
refractory lining is cooled with water.

The raw materials fed into the blast furnace are iron ore (e.g.
haematite), limestone and coke.

1-The iron ore is reduced by carbon monoxide to form iron metal.

The common ores of iron are haematite [iron (III) oxide], magnetite,
siderite [FeCO3] or limonite [Fe3O4].

2-The limestone/CaCO3 is used to flux or remove impurities from the

ore. Slag is formed.
3-Coke provides the heating fuel and forms the reducing agent CO.

The raw materials are fed into the blast furnace using a conveyer
belt. Hot air/oxygen is blown into the furnace through pipes called
tuyeres. The hot air is used to ignite the charge.

-The coke burns exothermically to produce heat and carbon dioxide

gas.

C + O2 CO2 ΔH = -285 kJ/mol

Impurities of sulphur and carbon burn to form SO2 and CO2 which
escape as gases.

-The heat given off decomposes the limestone (calcium carbonate) to

form calcium oxide and release more carbon dioxide gas.

CaCO3(s) heat CaO(s)+ CO2(g)

-The excess carbon dioxide gas reacts with more carbon (coke) to
form carbon monoxide gas. Carbon monoxide gas acts as a reducing
agent.

CO2(g) + C(s) 2CO(g)

- The carbon monoxide gas reduces the iron (III) oxide [haematite
ore] to form iron metal

Fe2O3(s) +3CO(g) 2Fe(s) + 3CO2(g)

-The lime or calcium oxide reacts with impurities from the ore such
as silicon dioxide/silica/sand to form calcium silicate (or slag). Slag is
used in the construction of roads and for foundations of houses.

CaO(s) + SiO2(g) CaSiO3(s) slag

The slag floats on top of the molten iron because it is less dense. The
hot iron is tapped out and solidifies into bars or ingots called pig iron
or cast iron. The slag is also removed by another tapping hole.

Properties of iron metal

1- The melting point of iron is 1535 °C. The density is 7,87g/cm3. The
boiling point is 2861°C.

2 Iron is malleable and ductile. It is grey.

3 Iron is workable and can be forged.

4 Iron can be alloyed to form steels. 5 Iron is magnetic

(ferromagnetic).

6 It shows common valencies of 2 and 3. (oxidation states +2 and +3).

There are three types of iron wrought iron, cast iron and pig iron.

Pig iron –this is the name given to iron straight from the blast
furnace. It is also called cast iron

wrought iron – This is iron whose carbon content has been reduced
and has a very small% of carbon. It is made from pig iron.

Uses of wrought iron-burglary bars and railings.

Cast iron- iron metal with a high carbon %, brittle. Resistant to wear.

Uses-engine blocks, vent pipes, drain cover (manhole covers)

steels- Steels are alloys of iron and other elements. Steels are made
by heating scrap steel/ pig iron with additives (Ni, Cr, Mn, V etc) in a
furnace called the Basic Oxygen furnace or Bessemer convertor. The
raw materials fed into the furnace include scrap steel, limestone,
coke, required additives e.g. Cr, Ni, Mn, W. Steels have desirable
properties e.g. corrosion resistance.
 Draw one diagram
Manufacture of steel -blow in oxygen gas into the furnace (with scrap
iron). Carbon and carbon dioxide form carbon dioxide and sulfur
dioxide which escape as waste gases.

C + O2 CO2 S + O2 SO2
- Phosphorus and silicon react with oxygen to form phosphorus oxide
or silicon oxide (are acidic) which are solids- add calcium oxide /
quicklime or calcium carbonate (limestone) which react with silicon
dioxide to form slag / calcium silicate.
2P +5/2 O2 P2O5 Si + O2 SiO2
P2O5 + 3CaO Ca3(PO4)2
CaO(s) + SiO2(g) CaSiO3(s) slag
-pure iron in the furnace reacts with nickel or manganese to form
steel.
name of steel composition properties uses

mild steel iron +carbon strong, malleable

stainless steel iron+chromium+nickel corrosion resistant cutlery , surgical equipment

chemical plants

tool steel iron + manganese very strong tools

hardsteel iron +manganese + Cr extremely hard, High rock crusher ,springs

tensile strength
(high speed steel)

Extraction of aluminium

The ore of aluminium is called bauxite, which is hydrated aluminium

oxide Al2O3, nH2O. It contains up to 60% Al2O3 and impurities of Fe2O3
and SiO2.

Purification of the ore-The bauxite ore is crushed and dissolved in aq

NaOH. This forms the sodium aluminate solution. The impurities are
filtered off. The filtrate of sodium aluminate solution which is heated
to form Al2O3 (pure alumina) which has a high melting point of

2050 °C. 2Al(OH)4- heat Al2O3 + 4 H2O

The electrolysis-The pure alumina is electrolysed in an electrolytic

tank. The pure Al2O3 is dissolved in molten cryolite (Na3Al F6) which
lowers the melting point of Al2O3 to about 900 to 1000 °C. The
electrolytic cell has a cathode lining of carbon/graphite and contains
anodes made of carbon/graphite. The electrolysis is carried out at a
high current of 150 000- 300 000A and 4-5V. This provides the
heating effect of a current which melts the ore. The aluminium oxide
ionises/dissociates as follows:

Al2O3 ⇌ 2Al3+ + 3O2- . The Al3+ ions migrate to the cathode and
are deposited as Al metal. The O2- migrate to the anode and are
deposited as O2 gas.

cathode reaction anode reaction

2Al3+ +6e- 2Al 2O2- O2 + 4e-
Al3+ + 3e- Al 2O2- O2 + 4e-

N.B. 1- The anodes have to be replaced periodically, before

they are worn out, because oxygen reacts with carbon and
carbon dioxide is evolved. C + O2 CO2
2 -Aluminium processing plants also give off toxic F2 gas. Lofty
towers are used.
Properties of aluminium
1 It is a shiny light metal.
2 It has a melting point of 660° C.
3 Aluminium is light but strong.
4 Aluminium is corrosion resistant because of the aluminium
oxide layer.
5 It has a density of 2,1g/cm3. It is non-toxic.
6 Aluminium is a good conductor of heat and electricity.
7 Aluminium is readily alloyed with other metals.
Uses of aluminium
1 To make cooking utensils because it is malleable
2 To make electric cables because it is a good conductor of
electricity. The cables have a strengthening core of steel.
3 To make food container, cooking foil and sauce pans,
because it is non-toxic and unreactive due to the oxide layer.
4 It is used to make alloys such as Alnico and Duralumin.
Duralumin is light but strong. It is used to make airframes and
aircraft bodies. Alnico is used to make electromagnets.

Al + Ni + Co alnico
Al + Mn + Mg + Cu duralumin.
5 To make window and door frames because it can be
anodised (decorated by dyes)