Copper, iron, and zinc are all extracted from their respective ores through different processes.

Copper is extracted from its ores such as chalcopyrite (CuFeS2) by a method depending on the nature

of the ore.

Sulfide ores are converted to copper by a different method from silicate, carbonate or sulfate

ores.

1. The concentrated ore is heated strongly with silicon dioxide (silica) and air or oxygen in

a furnace or series of furnaces.

2. The copper(II) ions in the chalcopyrite are reduced to copper(I) sulfide (which is reduced

further to copper metal in the final stage).

3. The iron in the chalcopyrite ends up converted into an iron(II) silicate slag which is removed.

Most of the sulfur in the chalcopyrite turns into sulfur dioxide gas1.

An overall equation for this series of steps is:

2CuFeS2+2SiO2+4O2→Cu2S+2FeSiO3+3SO2

The copper(I) sulfide produced is converted to copper with a final blast of air

Cu2S+O2→2Cu+SO2

The end product of this is called blister copper - a porous brittle form of copper, about 98 - 99.5%

pure1.Copper can also be extracted from non-sulfide ores by a different process involving three

separate stages: Reaction of the ore (over quite a long time and on a huge scale) with a dilute acid

such as dilute sulfuric acid to produce a very dilute copper(II) sulfate solution1

Extraction of Iron
The extraction of iron from its ore, typically hematite (Fe2O3) or magnetite (Fe3O4), involves several

stages in a process known as iron smelting. Here's a detailed breakdown of the steps involved, along

with the chemical equations:

1. **Mining**: Iron ore is first extracted from the ground in open-pit mines or underground mines,

depending on the depth and accessibility of the ore deposit.

2. **Crushing and Grinding**: The mined ore is crushed into smaller pieces to increase the

surface area for subsequent processing. It is then ground into a fine powder to facilitate

separation of the iron-containing minerals from the gangue (unwanted materials).

3. **Concentration of Ore**: Different techniques like magnetic separation, gravity separation,

and flotation are used to separate the iron-rich minerals from the gangue. **Chemical Equation for

Magnetic Separation**: Fe2O3 (hematite) + 3SiO2 (gangue) → 2Fe2O3·3SiO2 (ferrosilicate)

4. **Roasting and Calcination**: The concentrated ore is subjected to high temperatures in the

presence of air to remove any volatile impurities and convert iron sulfides to oxides. **Chemical

Equation for Roasting**: 4FeS2 (pyrite) + 11O2 → 2Fe2O3 (hematite) + 8SO2

5. **Reduction of Iron Oxide**: The iron oxide is reduced to iron using carbon monoxide (CO) or

hydrogen (H2) as reducing agents in a blast furnace. **Chemical Equation for Reduction using

Carbon Monoxide**: 3Fe2O3 + CO → 2Fe3O4 + CO2 Fe3O4 + CO → 3FeO + CO2 FeO + CO → Fe

+ CO2

6. **Formation of Slag**: The impurities in the ore combine with limestone (calcium carbonate)

to form slag, which floats on top of the molten iron. This slag is later removed. **Chemical

Equation for Formation of Slag**: CaCO3 (limestone) → CaO (calcium oxide) + CO2

CaO + SiO2 (silica from impurities) → CaSiO3 (slag)

7. **Casting and Solidification**: The molten iron is tapped from the bottom of the furnace and

cast into molds to form pig iron. Pig iron contains about 4% carbon and other impurities.

8. **Refining**: The pig iron is further refined in a basic oxygen furnace or an electric arc furnace to

reduce the carbon content and remove impurities like sulfur, phosphorus, and excess carbon.

**Chemical Equation for Refining in Basic Oxygen Furnace**: Pig Iron + Oxygen → Steel + Carbon

Monoxide

9. **Further Processing**: The steel produced from the refining process can be further processed to

create different types of steel with varying properties.

Iron is extracted from its ore in a blast furnace. The extraction of iron from its ore is a long and subdued

process, that helps in separating the useful components from the waste materials such as slag. The

concentrated ore is mixed with limestone (CaCO3) and Coke and fed into the blast furnace from the

top. It is in the blast furnace that extraction of iron occurs. The purpose of a Blast Furnace is to reduce

the concentrated ore chemically to its liquid metal state2.

Zinc is extracted from its principal ore, Zinc blend (ZnS), through a process known as froth floatation.

The concentrated ore is then roasted in excess air at 1200K to obtain zinc oxide (ZnO). It is then

reduced to Zn by coke at a temperature of 1673 K. The impure zinc obtained after reduction is purified

by electrolysis.