NARAYANA SR.

AIEEE MATERIAL 1 METALLURGY


METALLURGY SULPHIDE MINERALS:

SYNOPSIS
INTRODUCTION AND TERMS
 Metallurgy mainly deals with the methods of
extracting metals from minerals.
 The metals which occur to some extent in
native state (elemental) are Cu, Ag, Au, Pt,
Fe etc.,
 Generally metals occur as compounds in the
earth crust. The compounds of metals which
occur in earth crust, along with the earthy
impurities associated with them are called
minerals.
 The impurities present in the mineral are called  CARBONATE MINERALS:
Gangue (or) Matrix.
 All the minerals of a metal are not used for the
extraction of the metals.
 The mineral from which the metal can be
extracted very easily and economically is
known as an ore.
 All ores are minerals, but all minerals are not
ores.
 The selection of a mineral as an ore depends
on following factors
i) The percentage of metal in the mineral
ii) Nature and magnitude of impurities in the
mineral.
iii) The expenditure involved in the extraction
of metal from the mineral.
iv) The industrial utility of by-products produced
in the separation of metal from the mineral.
 Metals generally occur as their oxides,  HALIDE MINERALS:
carbonates, sulphides, chlorides, silicate
minerals.
 OXIDE MINERALS:
NARAYANA SR. AIEEE MATERIAL 2 Metallurgy

 SULPHATE MINERALS: OCCURRENCE OF METALS

 PHOSPHATE MINERALS:
 SILICATE MINERALS:
PRINCIPLES OF EXTRACTION
 The term metallurgy includes
i) concentration of the ore
ii) reduction of the ore iii) refining of metal
 The removal of the gangue from the ore is called
ore dressing (or) concentration of the ore.
 The separating of metal in crude form (impure
form) from the ore is called reduction of the
ore.
 The separation of a metal in pure state from
the crude metal is called refining of metal.
 The entire scientific and technological process
used for isolation of the metal from its ores is
known as metallurgy
 Elements vary in abundance. Among metals,
aluminium is the most abundant. It is the third
most abundant element in earth's crust (8.3%
approx. by weight). It is a major component of
many igneous minerals including mica and
clays. Many gemstones are impure forms of
Al2O3 and the impurities range from Cr (in 'ruby')
to Co (in 'sapphire'). Iron is the second most
abundant metal in the earth's crust.
Ex: Kaolinite (a form of clay) [Al2(OH)4 Si2O5]
Copper glance Cu2S
 The concentration of the ore can be done by
i) Hand picking
ii) Gravity method (washing with water)
iii) Froth floatation
iv) Magnetic separation
v) Liquation vi) Leaching
 The minerals available in nature contains
various impurities which are combined with
mineral physically or chemically.
 The substances which do not melt or become
soft even on strong heating are called refractory
substances.
Eg: Silica, quartz, calcia, magnesia, graphite,
chromite, bone ash etc.,
 Silica is an acidic refractory material. Calcia
and magnesia are basic refractory materials
Graphite, silicon carbide are neutral refractory
materials.
 The substance used to remove the gangue
from the ore in the form of easily fusible mass
is called a flux.
 The flux is added to the ore during the
metallurgical process and heated.
 The flux combines with the gangue and forms
a easily fusible mass called slag. The slag
can be very easily removed from the contents.
Gangue + flux = slag
 Fluxes are of two types
i) Acidic flux. Eg: Silica
ii) Basic flux. Eg: Calcia, magnesia.
 Acidic flux is used to remove gangue having
basic nature.
 Basic flux is used to remove gangue having
acidic nature.
 Haematite ore contains silica as impurity
(gangue). This impurity is removed by using
lime stone as flux.
NARAYANA SR. AIEEE MATERIAL
CaCO3  SiO2  CaSiO3  CO2
Flux Gangue Slag  Flue gas 
 In the extraction of copper from copper iron
pyrites, FeO is gangue. This is removed by
using silica as flux.
FeO  SiO2  FeSiO3
Gangue Flux Slag
 The waste gases produced during the
metallurgical process are called flue gases.
(Eg: CO2 , SO2 )
 Sand and small stones are removed by hand
picking method
 Haematite ore occurs as lumps. So it can be
very easily seperated from the impurities like
sand, stone pieces present along with it by
Hand picking.
 In washing method ore is made into fine
powder by using ball mills
 Ores like cassiterite and alluvial sand (contains
Gold) are concentrated by washing with water.
 Gravity method is based on the difference
between the densities of the ore particle and
gangue.
 Gravity process is used for the concentration
of denser ores from the water soluble and
lighter impurities (Gangue). Oxide ores and
carbonate ores are concentrated by this
method.
FROTH FLOATATION PROCESS
 This method is used when a higher ore
contains impurities having higher density.
 This method is used for the concentration of
Sulphide ores. (Eg: Copper pyrites, iron
pyrites, Galena, Zinc blende etc.,)
 In this process collectors and froth stabilisers
are added.
 Collectors (e.g., pine oils, fatty acids,
xanthates, etc.)
Froth Stabilisers (e.g., cresols, aniline)
 The mineral particles become wet by oils while
the gangue particles by water. A rotating paddle
agitates the mixture and draws air in it. As a
result, froth is formed which carries the mineral
particles. The froth is light and is skimmed
off. It is then dried for recovery of the ore
particles.
3 METALLURGY
 Sometimes it is possible to separate two
sulphide ores by adjusting proportion of oil to
water or by using 'depressants'.
Example: In case of an ore containing ZnS
and PbS, the depressant used is NaCN. It
selectively prevents ZnS from coming to the
froth but allows PbS to come with the froth.
ELECTROMAGNETIC PROCESS
 This method is used if the ore (or) gangue
particles are magnetic in nature.
 Tin stone ore is non magnetic. It contains
wolframite as impurity. The wolframite is
magnetic. The formula of wolframite is
FeWO4 .
 Haematite (or) Magnetite ore is magnetic. It
contains silica as impurity. The silica is non
magnetic.
LIQUATION PROCESS:
 This method is used if the ore contains high
melting gangue and easily fusible mineral
particles.
 Stibnite, an ore of antimony is placed on the
height of a slant surface and heated slowly.
The ore melts at 500 - 600°C and flows down
leaving behind the gangue.
TYPES OF FURNACES
 Furnace is a device in which high temperature
is produced either by burning a fuel (or) by
using electricity.
 Furnaces are lined with refractory bricks.
 The important parts in a furnace are
i) Hearth
ii) Fire place (fire box)
iii) Chimney
 In a furnace the ore is placed on the hearth.
 In a furnace the fuel burns in the fire place
 In a furnace the blue gases escape through
the chimney.
 The fire place and the hearth are seperated by
a partition known as fire bridge.
 The different types of furnaces used are
i) Reverberatory furnace
ii) Retort furnace
iii) Blast furnace
iv) Shaft furnace
v) Open hearth furnace
vi) Muffle furnace
vii) Electrical furnace
viii) Arc furnace
ix) Bessemer converter.
NARAYANA SR. AIEEE MATERIAL 4 Metallurgy

 The ore along with the substances added to it
(if any) is known as charge.
 The charge is placed on the hearth of a furnace.
REVERBERATORY FURNACE
 The principle involved in reverberatory furnace
is indirect heating.
 The hot gases and flames produced by the
burning of fuel in the fire box, reach the top of
the furnace and then reflected on to the hearth.
Na, K, Ca, Mg, Al etc.,
 The metals obtained by the reduction of their
ores with suitable reducing agent are
Zn, Sn, Cu, Fe etc.,
 Metal oxide ore on reduction with carbon or
coke gives metal. This method is used for the
extraction of metals like Zn, Sn etc.,
MxOy + yC  xM + y CO
o

The charge gets heated.

ZnO  C 
900 C
 Zn  CO
 The efficiency of the furnace is less because SnO2  2C 
1800 C o
 Sn  2CO
the heat content of waste gases cannot be
used repeatedly.  Haematite  Fe2O3  is reduced to iron mainly
 This furnace is used in the metallurgy of Cu, by carbon monoxide.
Pb, steel etc.,
BLAST FURNACE Fe2O3  3CO  2 Fe  3CO2
 The principle involved in blast furnace is direct  Metal oxide on reduction with hydrogen gas
heating. gives metal. This method is used for the
extraction of metals like Cu, W, Mo etc.,
 A conveyor belt called skiphoist carries the
charge to the top of the furnace. Mo O3  3H 2 
I .R
 Mo  3H 2O
 The charge is introduced into the furnace from o

the top by a special arrangement known as WO3  3H 2 

850 C
 W  3H 2O
double cup and cone arrangement. Cu2O  H 2  2Cu  H 2O
 Hot air is blown through a series of pipes called
 NiO is reduced to nickel by water gas.
tuyeres to heat the charge.
2 NiO   CO  H 2    2 Ni   CO2  H 2O 
o
300 C
 Molten mass (products) which collects at the
bottom of the furnace (i.e. hearth) is called
 Metal oxide on reduction with aluminium
smelt. powder gives metal. This is known as Gold
 The temperature of furnace at the top (near Schmidt alumino thermic process. This
cup and cone) is 400 - 500°C and at tuyere's method is for the extraction of metals like Cr,
region is  1500°C. Fe, Mn etc.,
EXTRACTION OF METAL o

REDUCTION OF THE ORES Cr2O3  2 Al 

600 C
 2Cr  Al2O3
 The separation of impure metal (crude metal)
Fe2O3  2 Al 
600 C o
 2 Fe  Al2O3
from the ore is called reduction of the ore.
 Generally oxide and halide ores are reduced. 3Mn3O4  8 Al 
600 C o
 4 Al2O3  9 Mn
 The reduction of the ore can be done by  The temperature of mixture in Alumino thermi
i) chemical methods process increases to 2500 - 3000°C due to
ii) electrolytical methods. the exothermic nature of reaction. So the metal
 The chemical methods are used for the is obtained in molten state in the reaction.
extraction of less electropositive metals from  Rubidium oxide on reduction with magnesium
their ores. gives rubidium.
 The commonly used reducing agents in Rb2O3  3Mg  2 Rb  3MgO
metallurgy are H 2 gas, CO gas, water gas,  'Al' can be extracted by passing current
Al , Mg , Ca metals, Coke. through a molten solution of Al2O3 and cryolite
 The electrolysis methods are used from the
 The alkali metals, Titanium, Tungsten, Uranium
extraction of highly electropositive metals from
are generally extracted by reducing their
their ores. halides with Mg, Ca, or by electrolysis.
 The metals generally obtained by the
electrolysis of their ores are
NARAYANA SR. AIEEE MATERIAL 5 METALLURGY

 TiCl4 on reduction with Mg gives  Some Sulphide ores on roasting gives metal
sulphate. This known as sulphatizing
titanium. UCl4 on reduction with calcium gives roasting.
uranium. o

7500 C ZnS  2O2 

650 C
 ZnSO4
TiCl4  2Mg  Ti  2MgCl2 Zinc blende

UCl4  2Ca  U  2CaCl2  Some sulphide ores on roasting gives metal

and sulphur dioxide. This is known as auto-
reduction (self-reduction).
 WCl6 on reduction with hydrogen gives
2Cu S  3O2  2Cu2O  2SO2
2
tungsten Copper glance

WCl6  3H 2  W  6 HCl
2Cu2O  Cu2 S  6Cu  SO2
 Self reduction method is used for the extraction
of metals like Cu, Hg, Pb etc.,
 Some sulphide ores are mixed with a chloride
salt and roasted. The sulphide ore changes
2Cu2 S  3O2  2Cu2O  2SO2 to chloride ore. This is known as chloridizing
2Cu2O  Cu2 S  6Cu  SO2 roasting.
o
 More electropositive metal can displace less Ag 2 S  2 NaCl  2O2 
600 C
 2 AgCl  Na2 SO4
electropositive metal from the aqueous solution Silver glance
of its salt. This is known as Hydro metallurgy.
 Copper can be obtained by adding iron to CALCINATION
aqueous CuSO4 solution. This is an example
 The process of heating an ore in the absence
for hydro metallurgy.
of air below its melting point is known as
CuSO4  Fe  FeSO4  Cu Calcination.
 Silver (Gold also) can be obtained by adding  The calcination process removes volatile
zinc to aqueous sodium argento cyanide impurities from the ore.
solution. This is an example for hydro  The calcination process some times results
metallurgy (Pyro metallurgy) in decomposition of the ore.
 The calcination process is used for oxide,
2Na  Ag  CN 2   Zn  Na2 Zn  CN 4   2 Ag carbonate and bicarbonate ores.
 The ore does not melt during calcination
2 Na  Au  CN  2   Zn  Na2  Zn  CN 4   2 Au
 Bauxite ore on calcination loses the moisture
ROASTING present in it.
 The process of heating an ore alone (or) mixed  Carbonate ores on calcination decomposes
with other substances in air below its melting
point is known as roasting.
giving metal oxide and CO2 .
 The roasting process removes volatile CaCO3  
 CaO  CO2
impurities from the ore.
Limestone
 The roasting process is used for sulphide ores.
 In roasting process air acts as oxidant. ZnCO3  ZnO  CO2
 Some sulphide ores on roasting gives metal Calamine
oxide and sulphur dioxide. This is known as
oxidizing roasting. MgCO3  MgO  CO2
Magnesite
2 ZnS  3O2 
high temp .
 2ZnO  2SO2
Zinc blende
2 NaHCO3  Na2CO3  H 2O  CO2
4 FeS2  11O2  2 Fe2O3  8SO2 baking soda
Iron pyrites
Fe2O3.xH2O(S)  Fe2O3 (s) + xH2O(g)
2Cu2 S  3O2  2Cu2O  2SO2
NARAYANA SR. AIEEE MATERIAL
SMELTING
 The process of separating molten metal in
crude form (or) mixture of metal sulphides in
molten form from the ore is called smelting.
 A mixture of haematite, coke and limestone
on heating in a blast furnace gives molten
iron.
 A mixture of copper iron pyrites, coke and sand
on heating in blast furnace gives Matte.
The matte is molten Cu2 S containing a little
FeS.
2CuFeS2  O2  Cu2 S  2 FeS  SO2
LEACHING PROCESS
 The ore is treated with a suitable solution. The
ore dissolves in solution leaving behind the
gangue. The solution is seperated from the
gangue.
 From the solution the ore is seperated in a
different chemical form.
 In leaching process mineral acids or aqueous
solution of reagent are used as leachal agent
 Bauxite on leaching with aqueous NaOH
solution gives NaAlO2 solution. Al  OH 3
is seperated from the solution at 473-523K
and 35-36 bar pressure
Al2O3  2 NaOH  2 NaAlO2  H 2O
 The aluminate in solution is neutralised by passing
CO2 gas and hydrated Al2O3 is precipitated. At
this stage, the solution is seeded with freshly
prepared samples of hydrated Al 2O 3 which
includes the precipitation:
2Na[Al(OH)4](aq)+ CO2(g)  Al2O3.xH2O(S) +
2NaHCO3 (aq)
 The sodium silicate remains in the solution
and hydrated alumina is filtered, dried and
heated to give back pure Al2O3.
Al2O3.xH2O(s) 1470 K Al2O3(s) + xH2O(g)

 OTHER EXAMPLES
In the metallurgy of silver and that of gold, the
respective metal is leached with a dilute
solution of NaCN or KCN in the presence of
air (for O2) from which the metal is obtained
later by replacement:
4M (s) + 8CN – (aq) + 2H 2 O (aq) + O 2 (g) 
4[M(CN)2]– (aq) + 4OH–(aq) (M= Ag or Au)
2[M(CN)2]- (aq) + Zn(s) 
[Zn(CN)4]2- (aq) + 2M (s)
6 Metallurgy
 Silver ore on leaching with aqueous NaCN
gives Na  Ag  CN 2  solution. Ag metal
is separates from this solution directly.
Ag 2 S  4 NaCN  2 Na  Ag  CN 2   Na2 S
2 Na2 S  2O2  H 2O  Na2 S 2O3  2 NaOH
Na2 S 2O3  2O2  2 NaOH  2 Na2 SO4  H 2O
2Na  Ag  CN 2   Zn  Na2 Zn  CN 4   2 Ag
 Silver and gold also extracted in this process
ELECTROLYTIC REDUCTION
 This method is used for the isolation of most
reactive metals and non metals like Na, K, Al,
Ca and F2 , Cl2
 Sodium is obtained by the electrolysis of
i) molten NaCl (Down's method)
ii) fused NaOH (Castner's method)
 Magnesium is obtained by the electrolysis of
fused MgCl2 .
 Aluminium is obtained by the electrolysis of
Al2O3 dissolved in molten cryolite. This is
known as Hall-Herault's method.
REFINING (OR) PURIFICATION
METHODS OF METALS
 The metal seperated from an ore generally
contains impurities. The impure metal is called
crude metal.
 The removal of impurities from crude metal is
called refining of metal.
 The methods used for refining of metals are
liquation, distillation, cupellation, poling
electrolysis, zone refining.
 Liquation method is used to refine metals
having low melting points. Eg. Tin, Lead,
Bismuth.
 In liquation method crude metal is placed on
the height of a sloping hearth and heated
slowly The metal melts and flows down,
leaving behind the impurity. The impurity left
behind is called dross.
 Distillation method is used to refine metals
having low boiling points. Eg: Zn, Cd, Hg.
NARAYANA SR. AIEEE MATERIAL 7 METALLURGY
 Metals containing non volatile impurities can VAPOUR PHASE REFINING
also be purified by distillation  In this method, the metal is converted into its
 In distillation method the crude metal is heated
volatile compound and collected elsewhere. It
in a retort. The metal distills over leaving the
impurity in the retort. is then decomposed to give pure metal So,
 Cupellation method is used to refine metals the two requirements are:
having easily oxidisable impurities. Eg. Ag.  (i) the metal should form a volatile compound
 Ag metal contains lead as impurity. The crude with an available regent.
silver metal is heated in a cupel (a small bowl  (ii) the volatile compound should be easily
type vessel) made of bone ash in free supply decomposable, so that the recovery is easy.
of air. Lead gets oxidised to PbO and goes  Example : Mond Process for Refining Nickel
out of the cupel leaving silver in pure state. (i) In this process, nickel is heated in a stream
 Poling method is used to refine metals having of carbon monoxide forming a volatile complex,
metal oxide as impurity. Eg. Cu, Sn nickel tetracarbonyl:
 In poling method, carbon powder is sprinkled
330  350 K
Ni + 4CO 
over the surface of molten crude metal and  Ni(CO)4
the mixture is stirred with poles of green wood. The carbonyl is heated to get pure metal
The reducing gases formed from wood and 450  470 K
carbon reduces the metal oxide impurity to Ni (CO)4   Ni + 4CO
metal.  (ii) Van Arkel Method for Refining Zirconium or
 Electrolysis method is used to refine metals Titanium:
like Cu, Ag, Au, Al. This method is very useful for removing all the
 In electrorefining method, impure metal is
oxygen and nitrogen present in the form of
taken as anode and pure metal is made
cathode. The electrodes are placed in acidified impurity in certain metals like Zr and Ti. The
aqueous solution of metal salt (or) molten crude metal is heated in an evacuated vessel
metal salt. On electrolysis, the metal in anode with iodine. The metal iodide being more
dissolves into the solution and gets deposited covalent, volatilises:
over the cathode. Zr + 2I2  ZrI4
 The residue left below anode in the electro  The metal iodide is decomposed on a tungsten
refining of metal is called anode mud. filament, electrically heated to about 1800K.
ZONE REFINING (OR) FRACTIONAL The pure metal is thus deposited on the
CRYSTALLIATION filament.
 This method is used to refine elements like ZrI4  Zr + 2I2
Si, Ge, Ga etc., EXTRACTION OF COPPER
 This method is used to produce ultra pure  Copper metal occurs in native state only to a
elements. small extent. The symbol "Cu" comes from
 This method is based on the difference in the the word "cuprum"
solubilities of impurities in the molten and solid  The important minerals of copper as oxides &
state of metal . sulphides are
 In this method a movable heater is fitted around Cuprite (or) ruby copper Cu2O
a rod of impure metal. As the heater moves
from one end to other end of the metal rod, Copper glance Cu2 S
the metal and impurities are seperated.
 The process is be repeated a number of times Copper pyrites CuFeS2
in the same direction.
CHROMATOGRAPHIC METHODS  Cu2 S .Fe2 S3 
 This method is based on the principle that
different components of a mixture are differently Malachite CuCO3 . Cu  OH 2
adsorbed on an adsorbent
 This is very useful for the purification of the Azurite 2CuCO3 . Cu  OH  2
elements which are available in minute  Copper is extracted from sulphide minerals
quantities and the impurities are not very (Copper iron pyrites).
different in chemical properties from the
element to be purified  The CuFeS2 ore is concentrated by froth
 Paper chromatography, column flotation process.
chromatography, gas chromatography are the
different chromatographic techniques
NARAYANA SR. AIEEE MATERIAL 8 Metallurgy

 The concentrated ore is roasted in a

reverberatory furnace. EXTRACTION OF ZINC
 The roasting process removes volatile  The zinc metal is called Yashada in Ayurvedic
impurities like As or Sb from the ore. medicine.
 Zinc metal does not occur in native state.
 The roasted ore contains Cu2 S , FeS and
 The minerals of zinc are
small quantities of Cu2O and FeO. Zinc blende ZnS
Cu2 S .Fe2 S3  O2  Cu2 S  2 FeS  SO2 Zincite ZnO
 The roasted ore is mixed with a little coke and Calamine ZnCO3
sand and smelted in blast furnace.
Franklinite ZnO.Fe2O3
2 FeS  3O2  2 FeO  2SO2
FeO  SiO2  FeSiO3 Willemite Zn2 SiO4  2 ZnO.SiO2 
 Zinc blende ore is crushed , washed with water
Cu2O  FeS  Cu2 S  FeO and then concentrated by
 The slag formed in the blast furnace is i) Gravity process using Wilfley's table.
ii) Froth floatation process.
FeSiO3 (Ferrous silicate).
 The zinc blende ore is subjected to
 The smelt formed in the blast furnace contains electromagnetic separation to remove iron
Cu2 S and a little FeS. This mixture is oxide impurity.
called copper matte.
 Zinc blende ore on roasting in free supply of
air gives ZnO, in rotary shelf burner.
 The copper matte is heated in Bessemer
converter lined inside with basic oxides such 2ZnS  3O2  2ZnO  2SO2
as lime (or) magnesia in presence of air and
sand. ZnS  2O2  ZnSO4
 In Bessemer converter all iron is removed as 2ZnSO4  2ZnO  2SO2  O2
FeSiO3 slag.  The calamine ore on calcination gives zinc
oxide
 In Bessemer converter Cu2 S undergoes self
reduction giving Blister copper.
ZnCO3  ZnO  CO2
 Blister copper is 98% pure copper.  The zinc oxide on reduction with carbon
powder gives zinc metal. This is known as
 Blister copper contains Cu2O as impurity.. Belgian process
 The molten blister copper is refined first by o

poling method and then by electrolysis. ZnO  C 

Thin plates of pure copper serves as cathode
which are coated with graphite and impure
copper plates act as anode. Electrolyte is
copper (II) Sulphate solution.
 The copper metal obtained by electro refining
is 100% pure.
 Copper has more affinity for sulphur and iron
has more affinity for oxygen. So smelt of blast
furnace contains more Cu2 S and a little FeS,
because FeO formed in blast furnace is
removed as FeSiO3 .
1100 C
Zn  CO
ZnO  CO  Zn  CO2
 The mixture of ZnO and coke is heated in fire
clay (or) earthern ware retorts, to which long
bent iron devices are attached. The long bent
iron devices are called prolongs. The fire clay
retorts and the prolong are as shown below.
 The fuel used in Belgian process is producer
gas.
 The zinc powder collected in the condensers
and prolongs is mixed with some zinc oxide.
This mixture is called zinc dust.
 The zinc metal collected in fused state is
solidified in moulds. This zinc is called Spelter.
NARAYANA SR. AIEEE MATERIAL
 The spelter is nearly 98% pure zinc.
 The impurities present in spelter are Cd, Pb.
 Zinc metal is refined by electrolysis.
 Roasted ZnS is digested in dilute H 2 SO4 .
Upon electrolysis it gives Zn at anode.
Impurities removed are As, Sb, Fe, Cu etc.
 In the electro refining of zinc
i) Anode - impure zinc
ii) Cathode - Pure zinc
iii) Electrolyte - aqueous ZnSO4 containing
H 2 SO4 .
 Commercial zinc contains 1.3% of lead, 0.1%
of Fe and traces of Cd and As.
 Commercial zinc is purified by liquation (or)
fractional distillation process.
EXTRACTION OF IRON AND TYPES OF IRON
 Iron occurs in native state in meteorites.
 The minerals of iron are
Haematite (reddish brown coloured) - Fe2O3
Magnetite (magnetic oxide) - Fe3O4
Limonite (hydrated oxide) - 2 Fe2O3 .3H 2O
Siderite (Spathic ore) - FeCO3
Iron pyrites - FeS2

Copper pyrites - CuFeS2
Iron can be obtained in three different forms.
They are
i) cast iron (or) pig iron
ii) wrought iron
iii) steel
MANUFACTURING OF CAST IRON
 This is the most impure form of iron.
It contains Fe = 93%, C = 4 - 5% and rest
Mn, P, Si etc.,
 Haematite or magnetite ore is washed with
water, mixed with a small amount of coal and
heated in free supply of air. The following
changes occur
i) The ore loses volatile impurities like
H 2O , CO2 , S & As.
ii) Siderite present in ore changes to FeO
iii) The FeO in the ore is oxidised to Fe2O3
iv) The ore becomes porous
9 METALLURGY
 The heated ore, coke and limestone are mixed
in 8 : 4 : 1 ratio by weights. This mixture is
called charge.
 The charge is heated in the blast furnace.
 In the blast furnace spongy iron is formed in
the zone of reduction (400 - 700°C)
Fe2O3  3C  2 Fe  3CO
Fe2O3  3CO  2 Fe  3CO2
 In the blast furnace CO2 is converted to CO
in the zone of heat absorption (800 - 1000°C)
CO2  C  2CO
CaCO3  CaO  CO2
 In the blast furnace slag is formed in the zone
of heat absorption .
CaO  SiO2  CaSiO3
 In the blast furnace coke is oxidised to CO2
in the zone of fusion (1200 - 1300°C)
C  O2  C O2
 In the blast furnace complete reduction of
Fe2O3 to iron takes place, in the zone of
fusion.
 In the blast furnace molten iron collects in the
bottom of the hearth and slag floats over it.
  1300 C 
0
 The molten iron obtained from blast furnace is
called pig iron.
 The waste gases know as "blast furnace gas"
escape from the top of the furnace.
 The pig iron on solidification is called cast iron.
 The slag formed in blast furnace is CaSiO3 .
 The pig iron on sudden cooling gives white
cast iron which contains carbon impurity in
the form of cementite.  Fe3C 
 The pig iron on slow cooling gives grey cast
iron which contains carbon impurity in the form
of graphite.
MANUFACTURING OF WROUGHT IRON .
 It is the purest form of iron. It contains Fe =
99.5%, C = 0.1 - 0.25% and rest Mn, P, Si
etc.,
 It is manufactured from cast iron by puddling
process.
NARAYANA SR. AIEEE MATERIAL
 Cast iron is heated in a reverboratory furnace,
the hearth of which is lined with basic lining of
Fe2O3 .
 The impurities in cast iron are oxidised by
Fe2O3 .
3C  Fe2 O3  2 Fe  3CO
3Si  2 Fe2O3  3SiO2  4 Fe
3Mn  Fe2O3  3MnO  2Fe
MnO  SiO2  MnSiO3
 Slag 
6P  5F e2O3  3P2O5  10Fe
P2O5  Fe2O3  2 FePO4
 Slag 
 The oxidised impurities form slags like
MnSiO3 , FePO4 etc.,
 The CO formed escapes and burns with blue
flames. The flames are known as Puddler's
candles.
 The molten mass on the hearth of the furnace
is taken out in the forms of balls with the help
of long iron rods.
 The iron balls are beaten under steam
hammers to squeeze out as much of slag as
possible.
 The fibrous nature of wrought iron is due to
small amount of slag present in it.
MANUFACTURING OF STEEL
 It is the most important commercial form of
iron. It contains 0.25 to 2% of carbon.
 It is manufactured from cast iron mainly by
two methods . They are
i) Bessemer converter process
ii) Open hearth process.
BESSEMER CONVERTER PROCESS
 If cast iron contains phosphorus as impurity,
the Bessemer converter is lined inside with
basic material like CaO (or) MgO.
 If cast iron contains Mn as impurity the
Bessemer converter is lined inside with acidic
material like silica.
10 Metallurgy
 The molten cast iron is taken in Bessemer
converter and air is blown in to it. The
impurities in the iron are oxidised and finally
form slags like

FeSiO3 , MnSiO3 , Ca3 PO4 2 etc., 
 The carbon monoxide formed burns at the
mouth of the furnace with blue flame. If the
blue flame suddenly dies out, it indicates
completion of oxidation of impurity and
formation of wrought iron.
 Calculated quantity of spiegeleisen is added
to the wrought iron formed to get manganese
steel.
 Spiegeleisen is an alloy of Fe, Mn (15-20%)
and carbon (60%).
 In this there is a loss of iron due to slag
formation and Mn reduces the loss of iron.
 Ferromanganese unites with O2 in the steel
after Bessemerization process.
  
The Ca3 PO4 2 formed as slag is known as
Thomas slag. it is used as a fertilizer.
 The quality of steel produced in this process
in not high.
OPEN HEARTH PROCESS
(SIEMENS - MARTIN PROCESS)
 This process is used to produce high quality
steel.
 The open hearth process works on the principle
of heat regeneration.
 The fuel in open hearth process is producer
gas or coal gas.
 The charge introduced into the open hearth
process consists of pig iron, iron ore ( Fe2O3 -
haematite) scrap iron, scrap steel and lime
stone.
 In open hearth process the quality of steel
produced can be analysed at desired intervals
of time.
 There is no loss of iron due to slag formation
in this process, as blast of air is not used.
EXTRACTION OF SILVER
 Silver occurs in native state associated with
Cu and Au in alluvial sands.
 The minerals of silver are
Argentite (or) Silver glance - Ag 2 S
Horn silver (or) Chlorargyrite - AgCl
Pyrargyrite (or) Ruby silver -
Ag3 SbS3  3 Ag 2 S .Sb2 S3 
 Argentiferous lead also contains silver.
NARAYANA SR. AIEEE MATERIAL 11 METALLURGY

 The anode mud obtained in the electrorefining PURIFICATION OF BAUXITE

of copper also contains silver.
 The silver is generally extracted from its
sulphide ores (or) halide ore by Mac Arthur -
Forrest process (or) Cyanide process.
 The argentite is concentrated by froth floatation
process.
 The concentrated ore is digested with a dilute
solution (1%) of sodium cyanide to get sodium
argento cyanide.
Ag 2 S  4 NaCN  2 Na  Ag  CN  2   Na2 S
 Air is blown into the solution to oxidise Na2 S
to Na2 SO4 .
 Aluminium is extracted from Bauxite Ore.
 White Bauxite contains silica  SiO2  as
impurity and purified by Serpeck's process.
 Red Bauxite contains FeO as impurity
 Concentration of Red Bauxite is done by
1. Baeyer's process 2. Hall's process
BAEYER'S PROCESS:
 Powdered Bauxite is first roasted to convert
ferrous oxide impurity present in it into ferric
oxide
 The roasted bauxite ore is dissolved in Conc.
NaOH solution at 423 K giving sodium meta
aluminate

2 Na2 S  2O2  H 2O  Na2 S 2O3  2 NaOH
Na2 S 2O3  2O2  2 NaOH  2 Na2 SO4  H 2O
 The oxidation of Na2 S to Na2 SO4 helps the
completion of reaction.
 Horn silver on leaching with dilute NaCN
solution gives sodium argento cyanide
AgCl  2 NaCN  Na  Ag  CN  2   NaCl
 Silver is precipitated from sodium argento
cyanide solution by adding zinc dust.
 The clear aqueous solution of NaAlO 2 is
diluted with water and pinch of Al  OH 3 is
added to it. The solution is agitated well.
Al  OH 3 added act as seeding agent.
NaAlO 2 undergoes hydrolysis giving
Al  OH 3
Al  OH 3 is ignited at 12000 C gives
 The

2 Na  Ag  CN 2   Zn  Na2  Zn  CN 4   2 Ag pure Al2O3 .

 Any metal which is more reactive or more  The pure Al2O3 is known as Alumina.
electro positive than silver can be used in place
of zinc in this process. Al 2O3 2H 2O  s   2NaOH  aq  
 The silver precipitated is fused with KNO3 to 2NaAlO 2 aq   3H 2O l 
oxidise any zinc present in it.
 The silver metal is purified by electrorefining. NaAlO 2 aq   2H 2O l   NaOH aq   Al  OH 3 
In this method
Anode - impure silver (contains Zn, Cu, Au , 12000 C
as impurities). 2Al  OH 3 
 Al2O3  3H 2O
Cathode - pure silver
HALL'S PROCESS:
Electrolyte - aqueous AgNO3 containing
 Bauxite is fused with Na 2 CO3 to get
HNO3
NaAlO 2 ,which is extracted with water..
 The silver metal can be obtained from
argentiferous lead by  CO 2 gas is passed into the aqueous solution
i) Parke's process
ii) Pattinson's process of NaAlO 2 to get Al  OH 3 .
EXTRACTION OF ALUMINIUM
 Aluminium is the third most abundant element  The Al  OH 3 on strong heating at 1200 C
found in nature next to oxygen and Si. gives alumina.
NARAYANA SR. AIEEE MATERIAL 12 Metallurgy

Al2 O3  Na 2CO3  2NaAlO 2  CO 2   F2 gas liberated at anode reacts with Al2O3

present in the electrolyte.
2NaAlO 2  3H 2O  CO 2 
2Al2O3  6F2  4AlF3  3O2
2Al  OH 3   Na 2CO3  The oxygen gas evolved reacts with carbon
powder, sprinkled on the surface of the
12000 C
2Al  OH 3 
 Al2O3  3H 2O electrolyte giving CO and CO 2 . Some of the
SERPECK'S PROCESS: oxygen escapes.
 Powdered Bauxite and Coke is heated in N2
HOOPE'S PROCESS:
at o
1800 C .
 ELECTROLYTE: Fused mixture of Fluorides
 AlN , Silicon vapor and CO gas are formed of sodium, Barium and Aluminium saturated
due to following reactions.
with Al2O3
18000 C
Al2O3  3C  N 2 
 2AlN  3CO   CATHODE: Pure Aluminium layer in which
graphite rods are suspended.
SiO 2  2C  Si  2CO 
 Anode: Impure Aluminium layer having
 AlN on hydrolysis gives Al  OH 3 and contact with carbon plate fixed at the bottom
of the electrolytic cell.
NH 3 gas.( bye product)
 Al  OH 3 on ignition gives Al2O3  The aluminium metal obtained in Hoope's
process is 99.98% pure.
 Pure Al2O3 is a bad conductor of electricity
EXTRACTION OF MAGNESIUM
and its fusion temperature is very high
HALL-HEROULT PROCESS:
Magnesium metal is industrially prepared from
 Al metal is obtained by the electrolysis of carnallite, magnesite or sea water.
Al2O3 dissolved in molten cryolite.
 FROM CARNALLITE:
 ELECTROLYTE: Al2O3 dissolved in molten a) Carnallite must be dehydrated to get
anhydrous mineral.
cryolite to which a small quantity of CaF2 is b) The removal of first four water molecules is
also added. easier but the removal of the remaining two
water molecules is difficult because they react
 Cryolite increases the conductivity and CaF2
chemically with MgCl 2 to form Magnesium
reduces the fusion temperature of Al2O3 .
oxide, which is an insulator.
 CATHODE: The carbon lining present inside
the electrolytic cell (an iron tank)
MgCl2  2H 2O  MgO  2HCl  H 2O
c) Carnallite is dehydrated in an atmosphere
a) Gas liberated -oxygen of HCl gas. Excess of hydrochloric acid
b) Cathode reaction: prevents the hydrolysis of MgCl 2 by its own
3 
4Al  12e  4Al water of crystallisation.
 ANODE: Bunch of graphite rods suspended d) The anhydrous carnallite is mixed with an
in the electrolyte. equal amount of NaCl and heated to 7000 C .
a) Gas liberated - Fluorine
The presence of KCl and NaCl in anhydrous
b) Anode reaction:
MgCl 2 prevents the hydrolysis giving
12F  6F2  12e 
Magnesium at cathode and chlorine at anode.
NARAYANA SR. AIEEE MATERIAL 13 METALLURGY

 MgCl 2  Ca  OH 2  Mg  OH 2  CaCl 2
at cathode : Mg   2 e  Mg
 MgSO 4  Ca  OH 2  Mg  OH 2  CaSO 4

at anode : 2Cl  Cl 2  2 e
b) Mg  OH 2 precipitated is converted into
e) In the electrolysis of carnallite:
CATHODE-Iron tank Magnesium chloride or Magnesium oxide.

ANODE-Graphite rod coated with Lead.

Mg  OH 2  2HCl  MgCl2  2H 2O
f) In the electrolysis of carnallite, chlorine gas 
collects in the porcelain hood which surrounds Mg  OH 2 
 MgO  H 2 O
the anode.
g) The air in the electrolytic cell is replaced by c) Electrolysis of MgCl 2 or MgO gives
hydrogen or coal gas to prevent the burning of Magnesium metal.
Magnesium. EXTRACTION OF SODIUM
 FROM MAGNESITE:  Sea water contains 2.0 to 2.9 % of NaCl.
a) Magnesite on calcination gives MgO and  Sodium is a highly reactive metal occuring in
CO 2 combined state.
 Sir Humphry Davy obtained sodium for the first

MgCO3 
 MgO  CO 2 time by electrolysis of fused caustic soda.
b) Magnesia is dissolved in fused mixture of  MINERALS OF SODIUM

MgF2 , BaF2 and NaF at 900  9500 C . Rocket salt - NaCl

The fused mixture on electrolysis gives Chile salt petre or - NaNO3
Magnesium. Caliche
c) In the electrolysis of Magnesia (MgO) cast
iron rods act as cathode and carbon rods act Saji Mitti - Na2CO3
as anode.
Mirabilite - Na2 SO4
d) Mixture of MgO and coke on heating to
Borax - Na2 B4O7 10 H 2O
20000 C . Magnesium metal condenses to a Tincal is crude borax. It contains nearly 55%
powder. This method is known as Hansging of borax.
Method.
 Compounds of alkali metals are stable to
(M.P of Mg  6500 C & B.P  11000 C ) thermal treatment.
e) In Pidgeon process Magnesium is obtained  Chemical displacement methods are not useful
as the alkali metals are highly reactive and
by the reduction of Magnesia or Magnesite
placed at the top of electro chemical series.
with Ferro silicon.  Alk ali metals cannot be extracted by
3MgO  FeSi  3Mg  FeSiO3 electrolysis of their aqueous solutions but are
obtained by electrolytic reduction of fused
compounds.
3MgCO3  FeSi  3Mg  FeSiO3  3CO 2  Sodium metal is obtained by
1) Castner's method
f) MgO can be reduced to Magnesium by 2 ) Down's method
Silicon or Calcium carbide.  CASTNER'S METHOD:
1. Electrolyte - Fused NaOH
2MgO  Si  2Mg  SiO 2 2. Cathode - Iron rod
3MgO  CaC2  3Mg  CaO  2CO 3. Anode - Nickel
( Anode and Cathode are separated by wire
 FROM SEA WATER: gauze mesh)
a) When slaked lime is added to sea water
 Cathode reaction - Na   e  Na
magnesium hydroxide is precipitated from
 Anode reaction
MgCl2 and MgSO4
NARAYANA SR. AIEEE MATERIAL 14 Metallurgy

4OH   2 H 2 O  O2  4e  G 0   RT ln K --------- (2)

Where K = Equlibrium constant for “reactant
2 Na  2 H 2O  2 NaOH  H 2
- product" system at T.
 The molten sodium metal formed in castner's
process is taken out form time to time using  If G is negative the equlibrium constant K
perforated ladles.
is positive in equation (1) this happens only
 Castner method is not an economical method.
 DOWN'S METHOD: when the reaction proceeds towards
1. Electrolyte - Molten NaCl products.
2. Cathode -Iron ring
CONCLUSIONS:
3. Anode -Graphite rod
(The Cathode and anode are separated by wire  When the value of G is negative in equation
gauze mesh which prevents mixing up of
(1), only then the reaction will proceed. If S
products)
4. Cathode reaction  Na   e  Na is positive, on increasing the temperature (T),

5. Anode reaction 2Cl   Cl2  2e 

 The melting point of pure NaCl is 8030 C .
This is decreased to 500  600 0 C by adding
a small quantity of anhydrous
CaCl2 or KCI
 The advantages of adding CaCl2 or KCl are:
1. The M.P. of NaCl is decreased, so the
wastage of fuel is reduced.
2. The vapour pressure of sodium at the
temperature of electrolysis is less. So
possibility of burning of sodium is minimised.
3. At the temperature of electrolysis, the loss
of sodium due to its dissolution in fused
eletrolyte is reduced.
S would increase
the value of
 H  T S  and then G will become
negative.
 If reactants and products of two reactions are
put together in a system and the net G of
the two possible reactions is -Ve, the overall
reaction will occur.
 The interpretation of above process involve
coupling of the two reactions. Such coupling
is easily understood through Gibbs energy
 G 
0
Vs T plots for formation of the oxides.
Ellingham Diagram:

THERMODYNAMIC PRINCIPLES OF METALLURGY

 Gibbs energy concept of thermodynamics

help us in understanding the theory of
metallergical transformations
 The change in Gibbs energy, G for any
process at any specified temperature, is
described by the equation
G  H  T S --------- (1)
H  enthalpy change
S  entropy change for the process.
 For any reaction, this change could also be
explained through the equation.
NARAYANA SR. AIEEE MATERIAL
GIBBS ENERGY ( ΔG 0 ) VS T PLOTS
 The graphical representation of Gibbs energy
was first used by H.J.T Ellingham.
 The diagram Provides the choice of reducing
agent in the reduction of oxides.
 The diagram helps us in predicting the feasibility
of thermal reduction of an ore.
 If G is  Ve the thermal reduction of an ore
is feasible
 Ellingham Diagram normally consists of plots
of G  Vs T for formation of oxides of
Elements i.e, for the reaction.
2 xM ( S )  O2 g   2 M x O( S )
In the above reaction S  Ve subsequently
G  Ve this results in positive slope of the curve.
 Each plot is a straight line except when some
change in phase (solid  liq (or) liq  Gas)
taken place.
The temperature at which such change occurs,
is indicated by an increase in the slope on
positive side.
Eg: In the Zn, ZnO plot, the melting is indicated
by an abrupt Change in the curve.
 There is a point in a curve below which G is
negative, so MxO is stable. Above this point,
MxO will decompose on its own.
 Although thermodynamically feasible, in
practice, magnesium metal is not used for the
reduction of alumina because the process will
be uneconomical
 The reduction of a metal oxide easier if the
metal formed is in liquid state at the
temperature of reduction. Due to this S
becomes + ve and G becomes -ve
LIMITATIONS OF ELLINGHAM DIAGRAM:
 The graph simply indicates whether a reaction
is possible or not. It does not say about the
kinetics of the reduction process.
 The interpretation of G 0 is always based on
equilibrium constant K (G 0  RTlnK ) ,
thus it is presumed that the reactants and
products are in equilibrium. But this is not
always true because the reactant or product
may be solid.
 Alumina can be reduced by magnesium by the
following conditions
The two equitations are
15 METALLURGY
2 4
a) Al2 O3  2Mg  2MgO  Al
3 3
b) 2Mg + O2  2MgO
 At the point of intersection of the Al2O3 and
MgO curves, the G 0 becomes ZERO for the
reaction:
2 4
Al2 O3  2Mg  2MgO  Al
3 3
Below that point magnesium can reduce
alumina.
 Temperatures below the point of instruction of
Al2O3 and MgO curves, magnesium can reduce
alumina. But the process will be uneconomical.
 The reduction of a metal oxide easier if the
metal formed is in the liquid state at the
temperature of reduction because the entropy
is higher if the metal is in liquid state than in
solid state.
ELECTROCHEMICAL PRINCIPLES OF METALLURGY
 In the reduction of a molten metal salt,
electrolysis is done. Such methods are based
on electrochemical principles which could be
understood through the equation
 G 0   nFE 0
n = no. of electrons
E 0 = electrode potential of the redox couple
formed in the system
 More reactive metal have large - ve values of
E 0 , then G becomes +ve, so their
0
reduction is difficult.
 If the difference of two
E 0 values corresponds
to a positive E 0 and consequently G 0
becomes negative, then less reactive metal
will come out of the solution and the more
reactive metal will go the the solution
Eg:- Cu 2  aq   Fe s   Cu s   Fe 2 aq 
Among zinc and iron scraps, iron scrap is used
for leaching copper ore because zinc costlier
than iron.
USES OF ALUMINIUM, COPPER, ZINC AND IRON
 (a) Aluminium foils are used as wrappers for
chocolates.
 (b) The fine dust of Al metal is used in paints and
lacquers
NARAYANA SR. AIEEE MATERIAL 16 Metallurgy

 (c) Used in the extraction of chromium and 10 Which of the following is not a mineral of
manganese from their oxides. calcium.
1. Limestone 2. Fluorospar
 (d) Copper is used for making electrical wires,
3. Gypsum 4. Argentite
water and steam pipes used in several alloys
11. Willemite is a
(brass, bronze, coinage alloy)
1. Sulphide mineral 2. Silicate mineral
 (e) Zinc is used for galvanising iron, also usxed 3. Carbonate mineral 4. Oxide mineral
in batteries and in many alloys Brass (Copper 12. The formula of calamine ore is
60% + Zinc 40%) german silver (Copper 25-30%
Zinc 25-30%, Ni 40-50%) 1. ZnS 2. FeCO3 3. ZnCO3 4. Cu2 S
 (f) Zinc dust is used as a reducing agent in the 13. Which of the following mineral contains two
manufacture of dye-stuffs paints, etc metals
 (g) Cast iron is used for casting stoves, railway 1. Carnallite 2. Dolomite
sleepers, gutter pipes, toys etc. 3. Asbestos 4. All
 (h) Nickel steel for making cables, automobiles 14. Which of the following is a hydrated oxide
and aeroplane parts. Chrome steel for cutting mineral
tools and crushing machines. 1. Zincite 2. Cassiterite
 (i) Stainless steel for cycles, automobiles, 3. Bauxite 4. Haematite
utensils, pens, etc. 15. Which of the following is a basic carbonate
LEVEL-1 mineral
MODEL QUESTIONS i) Malachite ii) Dolomite
1. Which of the following metal occurs in native iii) Azurite iv) Magnesite
state 1. Both i & iii 2. Both ii & iv
1. Ca 2. Au 3. Zn 4. Al 3. Both i & iv 4. Both iii & iv
2. The most electro positive metal among the MODEL QUESTIONS
following is PRINCIPLES OF EXTRACTION
1. Zn 2. Fe 3. Ca 4. Na 16. Hand picking method is used for the
3. The earthy impurities present in the mineral concentration of following ore
are called 1. Cassiterite 2. Haematite
1. flux 2. slag 3. Calamine 4. Galena
3. gangue 4. refractory material 17. Generally sulphide ores are concentrated by
4. The ore of aluminium is following process
1. Cryolite 2. Magnesite 1. Hand picking 2. Washing with water
3. Carnallite 4. Bauxite 3. Leaching 4. Froth floatation
5. Down's method is used for the extraction of 18. The process of heating an ore in the absence
1. Al 2. Na 3. Mg 4. Cu of air below in melting point is known as
6. The least electropositive metal among the 1. Calcination 2. Roasting
following is 3. Smelting 4. Poling
1. Au 2. Mg 3. Al 4. Zn 19. Method used for the concentration of tinstone
ore is
PRACTICE QUESTIONS 1. Hand picking 2. Froth floatation
7. Formula of ruby copper is 3. Magnetic separation 4. Leaching
1. Cu2O 20. The olive oil used in froth floatation process is
2. Cu2 S
called
3. CuCO3 .Cu  OH 2 4. CuFeS2 1. Frothing agent 2. Collecting agent
3. Conditioning agent 4. Lubricating agent
8. Which of the following is not a carbonate 21. The collecting agent in froth floatation process
mineral is
1. Siderite 2. Calamine 1. Sodium ethyl xanthate 2. Pine oil
3. Lime stone 4. Fluorospar 3. Lime 4. Water
9. Horn silver is 22. The magnetic impurity present in cassiterite
1. Carbonate mineral ore is
2. Chloride mineral 1. Silica 2. Wolframite
3. Sulphate mineral
4. Phosphate mineral 3. SnO2 4. Clay
NARAYANA SR. AIEEE MATERIAL 17 METALLURGY
23. Which of the following is an acidic refractory PRACTICE QUESTIONS
material 34. Horn silver ore is leached with aqueous NaCN
1. Calcia 2. Quartz solution. The product formed is
3. Graphite 4. Magnesite 1. Silver metal 2. Silver chloride
PRACTICE QUESTIONS 3. Silver cyanide
24. Liquation process is used for the concentration 4. Sodium argento cyanide
of following ore MODEL QUESTIONS
1. Stibinite 2. Tinstone REFINING OR PURIFICATION METHODS
3. Limestone 4. Haematite
25. In blast furnace haematite is reduced to iron 35. 100% copper is obtained from crude copper by
mainly by 1. Zone refining method 2. electrorefining
1. Coke 2. H 2 gas 3. liquation 4. poling
36. Commercial zinc is refined by
3. CO gas 4. Water gas 1. liquation 2. poling
MODEL QUESTIONS 3. electrolysis 4. amalgamation
EXTRACTION OF METAL- CHEMICAL REDUCTION 37. Liquation method is used to refine following
crude metal
26. The extraction of metal from the ore is 1. Silver 2. Lead
1. an oxidation process 3. Mercury 4. Copper
2. a reduction process 38. Metal refined by cupellation process is
3. a hydration process 1. Ag 2. Fe 3. Zn 4. Sn
4. a neutralisation process PRACTICE QUESTIONS
27. Carbon cannot be used to reduce 39. A metal contains, metal oxide as impurity. The
1. ZnO 2. SnO2 3. Fe2O3 4. Al2O3 method used to refine this metal is
1. Poling 2. Liquation
28. Water gas is the most suitable reducing agent
3. Cupellation 4. Distillation
to reduce
40. Which of the following metal is refined by
1. Al3O3 2. NiO 3. Cr2O3 4. Mn3O4 distillation method
PRACTICE QUESTIONS 1. Zinc 2. Iron 3. Tin 4. Copper
29. Hydro metallurgy is used in the extraction of 41. Which of the following metal is refined by poling
1. Cu 2. Al 3. Mg 4. Na process
30. Silver is displaced when zinc is added to 1. Na 2. Cu 3. Al 4. Zn
aqueous sodium argento cyanide This method 42. Zone refining method is used for refining
of extracting silver is an example for 1. Al 2. Ge 3. Cu 4. Fe
1. Leaching MODEL QUESTIONS
2. Hydro metallurgy EXTRACTION OF COPPER
3. Pyrometallurgy 43. The copper metal is extracted from its
4. Liquation 1. Carbonate ore 2. Sulphide ore
31. The weakest reducing agent among the 3. Sulphate ore 4. Chloride ore
following is 44. Copper matte is a molten mixture of
1. Hydrogen Gas 2. Coke 1. Cu2 S  little FeS 2. Cu2 S  little FeO
3. Carbon monoxide gas 4. Aluminium metal
MODEL QUESTIONS 3. Cu2O  little FeO 4. Cu2O  little FeS
LEACHING PROCESS 45. Which of the following metal is obtained by
32. Bauxite is boiled with aqueous NaOH solution. the reduction of metal oxide with Hydrogen
Sodium metal aluminate solution is formed. gas
This part in the metallurgy of Aluminium is 1. Cu 2. Al 3. Mg 4. Fe
called PRACTICE QUESTIONS
1. Liquation 2. Amalgamation 46. In the extraction of copper, the slag formed in
3. Leaching 4. Calcination the blast furnace is
33. Leaching process is one stage in the
metallurgy of 1. CaSiO3 2. FeSiO3
1. Zinc 2. Iron
3. Aluminium 4. Copper
3. Ca3  PO4  2 4. MnSiO3
NARAYANA SR. AIEEE MATERIAL 18 Metallurgy

47. The impurity present in Blister copper is MODEL QUESTIONS

EXTRACTION OF ALUMINIUM
1. FeS 2. Cu2O 3. Cu2 S 4. FeO
MODEL QUESTIONS
60. Aluminium is extracted from
EXTRACTION OF ZINC
1. Mabnetite 2. Bauxite
48. Which of the following metal cannot occur in
native state? 3. Aluminium 4. Haematite
1. Cu 2. Zn 3. Ag 4. Fe 61. Which is not a mineral of aluminium
49. Belgian process is used for the extraction of 1. Anhydrite 2. Bauxite
1. Cu 2. Ag 3. Zn 4. Fe 3. Corundum 4. Diaspore
PRACTICE QUESTIONS 62. The chief ore of aluminium is
50. The device known as prolong is used in the 1. Alunite 2. Bauxite
extraction of following metal 3. Cryolite 4. Felspare
1. Zn 2. Ag 3. Cu 4. Fe 63. Bauxite is an oxide mineral of
51. Spelter is impure form of
1. Barium 2. Boron
1. Zn 2. Ag 3. Cu 4. Fe
52. The fuel used in Belgian process is 2. Bismuth 4. Aluminium
1. Water gas 2. Producer gas 64. Which one of the following is used in the
3. Coke 4. Coal extraction of aluminium by electrolytic process
MODEL QUESTIONS
EXTRACTION OF IRON AND TYPES OF IRON 1. Al2O3 2 Al  OH 3
53. The magnetic oxide of iron is
1. Haematite 2. Magnetite 3. AlCl3 4. Al2  SO 4 3
3. Siderite 4. Limonite 65. Which of the following method is not used for
54. The most impure form of iron is the concentration of Bauxite ore
1. Wrought iron 2. mild steel 1. Serpeck's method 2. Baeyer's method
3. hard steel 4. cast iron 3. Hoope's method 4. Hall's method
PRACTICE QUESTIONS 66. When Baxuite is heated with NaOH solution,
the water soluble compound formed is
55. The slag formed in the blast furnace during
the extraction of iron from haematite is 1. NaAlO 2 2. Na 3AlO3
1. Ca3  PO4  2 2. CaSiO3 Al  OH 3
3. 4. Al2O3
3. FeSiO3 4, MnSiO3 PRACTICE QUESTIONS
56. The iron formed in blast furnace is called
1. Pig iron 2. Wrought iron
67. A mixture of White Bauxite powder and coke
3. Steel 4. Cast iron
is heated in nitrogen gas very strongly. The
MODEL QUESTIONS
products are
EXTRACTION OF SILVER
57. Mac Arthur - Forrest process is used for the 1. Al2O3 , C 2 N 2
extraction of
1. Cu 2. Ag 3. Fe 4. Zn 2. Al  NO3 3 , CO
PRACTICE QUESTIONS
3. A l N, CO,Si vapour
58. From Na  Ag  CN  2  solution silver can be 4. Al 2  CO3 3 , N 2 O
displaced by 68. Aluminium is obtained by the electrolysis of
1. Zn 2. Al 3. Ca 4. All
59. Parke's method is used to separate silver from
pure Al2O3 dissolved in
1. Alumina 2. Bauxite
1. Ag2 S 2. AgCl
3. Cryolite 4. Felspar
3. argentiferous lead 4. alluvial sand
NARAYANA SR. AIEEE MATERIAL 19 METALLURGY
69. Which of the following technique is used in 77. The mineral of Magnesium is
the manufacture of aluminium from bauxite 1. Bauxite 2. Malachite
1. Reduction with magnesium 3. Carnallite 4. Haematite
2. Reduction with coke 78. A mixture of magnesite and ferro silicon on
3. Electrolytic reduction strong heating gives
4. Reduction with iron
70. In the electrolysis of alumina cryolite is added 1. Mg 2. Fe 3. Si 4. MgSO 4
to PRACTICE QUESTIONS
1. Lower the melting point of alumina
79. Hydrated magnesium chloride becomes
2. Increase the electrical conductivity
anhydrous salt when it is heated.
3. Minimise the anode effect
4. Remove impurities from alumina 1. With P4O10
71. In the extraction of aluminium the electrolyte
is 2. With anhydrous CaCl2
1. Fused cryolite with felspar
3. In dry HCl gas 4. With conc. H 2SO 4
2. Fused cryolite with fluorspar
3. Pure alumina in molten cryolite with 80. Metal extracted from sea water is
fluorospar 1. Be 2. Mg 3. Ba 4. Ca
4. Pure alumina with bauxite and molten 81. Magnesium is realted diagonally to
cryolite 1. Be 2. Ca 3. Li 4. Si
72. Cryolite is used in the electrolytic extraction 82. Magnesium burns in carbon dioxide giving the
of aluminium products. The formulae of the products are
1. To dissolve Alumina 1. MgO,C 2. Mg,CO
2. To dissolve sodium
3. To dissolve aluminium fluoride 3. MgO2 , C 4. Mg  OH 2 , O 2
4. To decrease the solubility
MODEL QUESTIONS 83. Electrolysis of fused KCl.MgCl2 gives
EXTRACTION OF MAGNESIUM 1. Potassium only
2. Magnesium only
73. The metal obtained in pidgeon process is 3. Magnesium and Chlorine
1. Na 2. Mg 4. Potassium, Magnesium and Chlorine
3. Ca 4. Al MODEL QUESTIONS
74. The formula of Dolomite is EXTRACTION OF SODIUM
84. The formula of the most abundant salt of sodium
1. MgCO3 .CaCl 2 2. MgCO3 .CaCO3
in nature is
3. MgCO3 .CaSO 4 4. MgCl 2 .CaCO3
1. NaNO3 2. NaCl 3. Na2CO3 4. Na2 SO4
75. Composition of carnallite is
85. Chile salt petre is the nitrate mineral of
1. CaCO3.MgCO3 1.Potassium 2. Sodium
3. Calcium 4.Lithium
2. MgCl 2 .KCl.6H 2O
86. In Down's process a small amount of KCl is
3. Al2O3.2H 2O added to NaCl
1. To decrease melting point of NaCl
4. MgSO 4 .7H 2O 2. To increase electrical Conductivity
76. Anhydrous Magnesium chloride can be 3. To maintain electrical contact
prepared by heating MgCl 2 .2H 2O 4. To prevent oxidation of sodium metal formed
87. Molten NaCl conducts electricity due to the
1. in a current of dry HCl 2. with carbon
presence of
3. until it fuses 4. with lime
1. Free molecules 2. Free ions
3. Free electrons 4. Free atoms
NARAYANA SR. AIEEE MATERIAL 20 Metallurgy

88. In Down's process sodium is obtained by the

PRACTICE QUESTIONS
electrolysis of
98. Gelena [PbS] on heating in limited supply of
1. Molten NaOH 2. Molten NaCl
air gives lead metal. This is known as
3. Aqueous NaOH 4. Aqueous NaCl 1. Smelting 2. Calcination
PRACTICE QUESTIONS 3. Self reduction 4. Sulphatizing roasting
89. Glauber salt is a 99. A mixture of Haematite, coke and limestone
1. hepta hydrate 2. deca hydrate on heating in blast furnace gives molten iron
metal. This is known as
3. penta hydrate 4. dihydrate
1. Smelting 2. Calcination
90. Oxone is a compound of 3. Roasting 4. Liquation
1. Potassium 2. Sodium 100. Which of the metal can be obtained directly
3. Barium 4. Lithium during the roasting of its sulphide ore
91. Tincal contains mainly 1. Cu 2. Zn 3. Fe 4. Ca
MODEL QUESTIONS
1. NaNO3 2. Na2 B4O7 ,10 H 2O REFINING OR PURIFICATION METHODS
101. Ultrapure elements are obtained in the
3. Na2CO3 4. Na2 SO4 following method of metal refining
1. Electrolysis 2. Poling
92. In the Castner process for the extraction of 3. Liquation 4. Distillation
sodium, the anode is made of .....metal. 102. The solubility of the impurities in the metal in
(EAMCET - 2003) molten and solid states is different. This is
1. Copper 2. Iron the principle involved in the refining of metal
3. Sodium 4. Nickel by following method
1. Poling 2. Liquation
93. In the castner's process of extraction of
3. Zone refining 4. electrolysis
sodium the cathode is (2000 E)
PRACTICE QUESTIONS
1. Iron rod 2. Nickle rod
103. The method used to refine copper metal is
3. Copper rod 4. Graphite rod
1. Liquation 2. Distillation
LEVEL-II 3. Zone refining 4. electrolytic method
MODEL QUESTIONS MODEL QUESTIONS
PRINCIPLES OF EXTRACTION EXTRACTION OF COPPER
94. The froth floatation process is used for the 104. In the extraction of copper the smelt formed in
concentration of the blast furnace contains
1. ore having low density
2. ore having magnetic nature 1. Cu2 S + little FeS
3. ore having high density
4. ore having water soluble gangue
2. Cu2 S + little FeO
95. The flux used in the extraction of iron from 3. Cu2O + little FeS
Haematite in the blast furnace is
1. Lime stone 2. Silica 4. Cu2O + little FeO
3. Coke 4. Quartz
96. The slag formed in the extraction of iron from PRACTICE QUESTIONS
haematite in the blast furnace is
105. The Cu2O impurity present in blister copper
1. FeSiO3 2. CaSiO3 is removed by
1 liquation 2. distillation
3. MgSiO3 4. Ca3  PO4  2 3. poling 4. zone refining
97. The blue gas produced during the calcination 106. In Bessemer converter Cu2 S is converted to
of magnesite ore is
blister copper by
1. SO2 2. O2 3. CO2 4. CO 1. self reduction 2. reduction with coke
3. reduction with coal gas
4. reduction with H 2 gas
NARAYANA SR. AIEEE MATERIAL 21 METALLURGY
MODEL QUESTIONS MODEL QUESTIONS
EXTRACTION OF IRON AND TYPES OF IRON EXTRACTION OF ALUMINIUM
107. In the extraction of iron from haematite, the
charge used is haematite, coke and lime stone
114. The cathode used in the electrolytic cell during
in the following weight ratio
aluminium extraction is made of
1. 1 : 1 : 1 2. 8 : 4 : 1
3. 8 : 1 : 4 4. 1 : 4 : 8 1. Aluminium 2. Carbon Iining
108. In the blast furnace the reaction that occurs in 2. Iron 4. Steel
the zone of heat absorption is 115. Method used to refine Aluminium metal is
1. CO2  C  2CO 1. Baeyer's method 2. Hall's method
3. Serpeck's method 4. Hoope's method
2. Fe2O3  3CO  2 Fe  3CO2 PRACTICE QUESTIONS
116. During electrolytic reduction of Alumina, the
3. C  O2  CO2 reaction at cathode is (2001)
4. FeO  SiO2  FeSiO3 1. 2 H 2 O2  O2  4 H  4e 
109. Puddling process is used in the manufacture
of 2. 3 F   3 F  3e 
1. Wrought iron 2. Pig iron
3. Steel 4. Cast iron 3. Al 3  3e   Al
110. Cast iron contains phosphorus as impurity. In
Bessemarisation of this cast iron, the slag 4. 2 H   2e   H 2
formed is
117. Observer the following statements regarding
1. FePO4 2. Ca3  PO4  2 purification of bauxite:
1. During Hall's process, silica, is removed as
3. MnPO4 4. Zn3  PO4  2 Si(vapour)
PRACTICE QUESTIONS II. Bauxite ore contaminated with Fe2O3 is
111. The calcium phosphate slag is commercially
purified in Baeyer's process.
known as
III. During Serpeck's process, AlN is formed
1. Thomas slag 2. Baeyer's slag
The correct answer is:
3. Wohler's slag 4. Matte 1) I , II and III are correct
112. W hich of the following is not a correct 2) Only I and II are correct
statement 3) Only I and III are correct
1. White cast iron contains carbon in the form 4) Only II and III are correct
of Fe3C
2. Grey cast iron contain carbon in the form MODEL QUESTIONS
of graphite. EXTRACTION OF MAGNESIUM
3. The quality of steel produced in Bessemer
converter is very high 118. A mixture of Magnesium chloride and calcium
4. The quality of steel produced in open carbide on heating gives magnesium metal.
hearth process can be checked from time to
time. In this process calcium carbide is
113. Which of the following statement is wrong 1. Oxidising agent2. Reducing agent
1. The fibrous nature of Wrought iron is due 3. Neither oxidising nor reducing agent
to the slag present in it. 4. Dehydrating agent
2. The loss of iron is Bessemer process is 119. In the extraction of magnesium metal by
due to the formation of FeSiO3 slag. pidgeon process, the reducing agent is
3. In Bessemer process carbon monoxide 1. Carbon 2. Aluminium
formed burns with blue flame at the mouth 3. Ferro Silicon 4. Carbon monoxide
of the furnace.
4. In blast furnace Fe2O3 is reduced to iron
mainly by coke.
NARAYANA SR. AIEEE MATERIAL 22 Metallurgy

PRACTICE QUESTIONS PRACTICE QUESTIONS

120. W hen magnesium burns in steam. the 125. What is the reaction occuring at the anode in
formulae of the products are Down's process for the extraction of sodium?
1. Mg  OH  , H 2 2. MgO, H 2 (2000 E)
1. 4OH   2 H 2 O  O2  4e 
3. MgO 2 , H 2 4. Mg  OH 2 .O 2
2. Na   1e   Na
121. A piece of Magnesium ribbon was heated to
redness in nitrogen gas and then dropped into 3. 2 C l   C l 2  2 e 
water. The gas evolved is
4. NaOH  Na   OH 
1. NH 3 2. H 2 3. O2 4. N 2 126. Electrolysis of molten NaCl gives
(KCET, 1990)
122. Assertion (A): Anhydrous MgCl 2 is prepared
1. Na and H 2 2. Na and O2
by heating MgCl 2 . 6H 2O is a current of
HCl gas 3. H 2 and O2 4. Na and Cl2
Reason (R) : Presence of HCl gas checks 127. During the electrolysis of fused NaCl, the
reaction at anode is
up the hydrolysis of MgCl 2 by its water of (KCET, 1990)
crystallisation
1. Both A and R are true and R is correct 1. Cl  ions are oxidised
explanation of A 2. Cl  ions are reduced
2. Both A and R are true and R is not correct
explanation of A 3. Na  ions are oxidised
3. A is true but R is false
4. A is false but R is true 4. Na  ions are reduced
MODEL QUESTIONS LEVEL – III
EXTRACTION OF SODIUM MODEL QUESTIONS
128. Bessemerisation is carried out for
123. Molecular formula of Glauber salt is 1) Fe, Cu 2) Cu, Al
1. CuSO4 .5 H 2O 3) A.l, Ag 4) Fe, Al
129. Which of the following set of elements
2. MgSO4 , 7 H 2O mostly occur as sulphide ores.
1) Zn, Cu, Na 2) Zn, Cu, Pb
3. Na2 SO4 ,10 H 2O 3) Fe, Al, Ti 4) Cu, Ag, Au
130. Column – I Column – II
4. FeSO4 , 7 H 2O (Metals) (Ores)
124. In Down's process for the extraction of A) Tin p) Calamine
sodium, the melting point of NaCl is lowered B) Zinc q) Cassiterite
from 8030 C to 600 0 C C) Titanium r) Cerrusite
D) Lead s) Rutile
a) In order to avoid vaporisation of metallic
A B C D
sodium
1) 1 2 3 4
b) In order to avoid corrosive action of
2) 2 1 4 3
sodium and chlorine on the vessel at the high
3) 4 3 2 1
temperature
4) 2 1 3 4
c) by mixing sufficient amounts of KCl and
KF 131. A solution of Na2 SO4 in water is electrolysed
1. Only 'a' is correct using inert electrodes. The products at cathode
2. 'a' & 'b' are only correct and anode are respectively
3. a & c are only correct
4. a, b, c are correct 1) O2 ; H 2 2) O2 ; Na

3) H 2 ; O2 4) O2 ; SO2
NARAYANA SR. AIEEE MATERIAL 23 METALLURGY
132. Froth floatation process for the concentration 138. The method of zone refining of metals is
of sulphide ores is an illustration of the based on the principal of
practical application of 1) Greater mobility of the pure metal than
1) adsorption 2) absorption that of impurity
3) sedimentation 4) coagulation 2) Higher melting point of the impurity than
133. If a metal has low oxygen affinity then the
that of the pure metal
purification of metal may be carried out by
3) Greater noble character of the solid metal
1) liquation 2) distillation
3) zone refining 4) cupellation than that of the impurity
PRACTICE QUESTIONS 4) Greater solubility of the impurity in the
134. In the extraction of copper, metal is formed in molten state than in the solid
the Bassemer converter due to reaction 139. The anode mud in the electrolytic refining of
silver contains
1) Cu2 S  2Cu2O  6Cu  SO2
1) Zn, Cu, Ag, Au 2) Zn, Ag, Au
2) Cu2 S  2Cu  S 3) Cu, Ag, Au 4) Au only
140. Find the incorrectly matched pair
3) Fe  Cu2O  2Cu  FeO Ores Metals
1) Sylvine - Potassium
4) 2Cu2O  4Cu  O2
2) Malachite - Magnesium
135. In van Arkel method, if I 2 is introduced at 3) Cinnabar - Mercury
1700 K over impure metal, the product will be 4) Fluorite - Calcium
1) Iodide of the metal LEVEL – IV
2) No reaction takes place MODEL QUESTIONS
3) Impurities react with iodine 141. Ellingham diagram represents
4) Metal doesn’t react 1) change of G with temperature
136. In the leaching of Ag 2 S with NaCN, a 2) change of H with temperature
stream of air is also passed. It is because of 3) change of G with pressure
1) reversible nature of reaction between
4 change of  G  T S  with temperature
Ag 2 S and NaCN
142. The metal X is prepared by the electrolysis of
2) to oxidize Na2 S formed into Na2 SO4 fused chloride. It reacts with hydrogen to
and sulphur form a colourless solid from which hydrogen
3) both (1) and (2) gas is released on treatment with water. The
4) both are not suitable
metal is
137. Froth flotation process used for the
concentration of sulphide ore 1) Al 2) Ca 3) Cu 4) Zn
a) is based on the difference in wettability of 143. Select correct statement
different minerals a) the decomposition of an oxide into oxygen
b) uses sodium ethyl xanthate, C2 H 5OCS 2 and metal vapour entropy increases
Na as collector b) decomposition of an oxide is an endothermic
c) uses NaCN as depressant in the mixture
change
of ZnS and PbS when ZnS forms
soluble complex and PbS forms froth
c) to makeG o negative, temperature should
1) (a), (b) only correct be high enough so that T S o  H o
2) (b), (c) only correct 1) (a), (b) only correct
3) (a), (c) only correct 2) (b), (c) only correct
4) (a), (b), (c) are correct 3) (a), (c) only correct
4) (a), (b), (c) correct
NARAYANA SR. AIEEE MATERIAL 24 Metallurgy

144. In the extraction of aluminium 149. Which of the following reaction does not
Process X: applied for red bauxite to remove occur in Bessemer’s converter?
iron oxide (chief impurity)
1) 2Cu2 S  5O2  2CuSO4  2CuO
Process Y: applied for white bauxite to
remove Z (chief impurity) then, Process X 2) 2Cu2 S  3O2  2Cu2O  2SO2 
and impurity Z are
1) X = Hall - Heroult’s process & Y= SiO2 3) 2CuFeS 2  O2  Cu2 S  2 FeS  SO2

2) X = Baeyer’s process and Y = SiO2 4) FeO  SiO2  FeSiO3

3) X = Serpeck’s process and Y = iron oxide 150. Blister copper is refined by stirring molten
4) X = Baeyer’s process and Y = iron oxide impure metal with green logs of wood
145. The oxide of a metal (R). can be reduced by because such a wood liberates hydrocarbon
the metal (P) and metal (R) cam reduce the gases (like CH 4 ). The process X is called
oxide of metal (Q). Then the decreasing order
of the reactivity of metal (P), (Q) and (R) with ……… and the metal contains impurities of
oxygen is Y is…….
1) P > Q > R 2) P > R > Q 1) X = cupellation, Y = CuO2
3) R > P > Q 4) Q > P > R
PRACTICE QUESTIONS 2) X = polling, Y = Cu2O
146. Give the correct of initials T or F for following 3) X = polling, Y = CuO
statements. Use T if statement is true and F 4) X = cupellation, Y = CuO
if it is false. LEVEL –V
(i) In gold Schmidt thermite process MORE THAN ONE ANSWER.
aluminium acts as a reducing agent
151. Pick up the correct statement(s)
(ii) Mg is extracted by electrolysis of aq.
1) all minerals are ores
Solution of MgCl2 2) all minerals cannot be an ore
(iii) Extraction of Pb is possible by smelting
3) all ores are minerals
(iv) Red bauxite is purified by Serpeck’s
process 4) the minerals from which metals can be
1) TTTF 2) TFFT 3) FTTT 4) TFTF extracted profitably are called ores
147. Give the correct order of initials T or F for 152. The process by which lighter earthy particles
following statements. Use T if statement is
are freed from the heavier particles using
true and F if it is false.
(i) Every mineral is an ore but every ore is water is/are
not a mineral 1) gravity separation 2) Levigation
(ii) Slag is product formed during extraction 3) Hydraulic washing 4) Leaching
of metal by combination of flux and
153. Which of the following process makes the
impurities.
(iii) Highly pure metals can be obtained by ore porous
zone refining 1) Roasting 2) Calcination
(iv) Carnallite is an ore of magnesium and 3) Reduction 4) Distillation
sodium
154. The extraction of metals from oxide ores
1) TTTF 2) FTTF 3) FTTT 4) TFTF
148. Choose the correct code regarding Roasting involve
process 1) Reduction with carbon
(I) It is the process of heating ore in air to 2) Reduction with aluminium
obtain the oxide
3) Electrolyte reduction
(II) It is an exothermic process
(III) It is used for hydrated oxide and oxy salt 4) Reduction with CO
ore 155. Metals which can be extracted by smelting
(IV) It is used after the concentration of ore process are:
1) I, II and III 2) I, II and IV
1) Pb 2) Fe
3) I, III and IV 4) I, II, III and IV
3) Zn 4) A1
NARAYANA SR. AIEEE MATERIAL 25 METALLURGY
ASSERTION-REASON TYPE QUESTIONS electrolyte. The anode consists of carbon rods
The questions given below consist of suspended from the top of the tank. Magnesium
“Assertion” and their “Reason”. Use the metal is liberated at the cathode in the molten
following key to choose the appropriate state.
answer. 162. Magnesium is obtained from magnesite by
1) If both assertion and reason are 1) calcination 2) Roasting
CORRECT, and reason is the CORRECT 3) Smelting 4) Poling
explanation of the assertion 163. The reaction at cathode is
2) If both assertion and reason are 
CORRECT, but reason is NOT the 1) Mg  Mg+2 + 2 e
CORRECT explanation of the assertion 
2) Mg+2 + 2 e  Mg
3) If assertion is CORRECT but reason is

INCORRECT 3) 2Cl   Cl2 + 2 e
4) If assertion is INCORRECT but reason is 
CORRECT 4) Cl2 + 2 e  2Cl 
156. ASSERTION: In the extraction of Ag, 164. In the commercial process Magnesium oxide
complex Na [Ag(CN)2] is reacted with Zn. is mixed with
REASON: Zn is d- block transition metal. 1) Mg F2 2) BaF2
157. ASSERTION: In froth floatation process 3) NaF
sodium ethyl xanthate is used as collector 4) Fluorides of Mg,Ba & Na
REASON: Sulphide ores are water soluble. KEY
1) 2 2) 4 3) 3 4) 4 5) 2
158. ASSERTION: CuFeS2 is concentrated by
6) 1 7) 1 8) 4 9) 2 10) 4
froth floatation method.
11) 2 12) 3 13) 4 14) 3 15) 1
REASON: CuFeS2 is main ore of copper.
16) 2 17) 4 18) 1 19) 3 20) 1
159. ASSERTION: Wrought iron is more
21) 1 22) 2 23) 2 24) 1 25) 3
malleable and ductile than steel.
26) 2 27) 4 28) 2 29) 1 30) 2
REASON : It contains slightly less
31) 1 32) 3 33) 3 34) 4 35) 2
percentage of carbon.
36) 1 37) 2 38) 1 39) 1 40) 1
MATRIX MATCHING
41) 2 42) 2 43) 2 44) 1 45) 1
160. Column - I Column - II
46) 2 47) 2 48) 2 49) 3 50) 1
A) Poling P) Titanium
51) 1 52) 2 53) 2 54) 4 55) 2
B) Cupellation Q) Copper
56) 1 57) 2 58) 4 59) 3 60) 2
C) Electro-refining R) Silver
61) 1 62) 2 63) 4 64) 1 65) 3
D) Van Arkel method S) Tin
66) 1 67) 3 68) 3 69) 3 70) 2
161. Column - I Column - II
71) 3 72) 1 73) 2 74) 2 75) 2
(Metal) (Process involved
76) 1 77) 3 78) 1 79) 3 80) 2
in commercial
81) 3 82) 1 83) 3 84) 2 85) 2
extraction from
86) 1 87) 2 88) 2 89) 2 90) 2
their ore)
91) 2 92) 4 93) 1 94) 1 95) 1
A) Pb P) Bessemerisation
96) 2 97) 4 98) 3 99) 1 100) 1
B) Cu Q) Roasting
101) 4 102) 3 103) 4 104) 1 105) 3
C) Zn R) Pyrometallurgy
106) 1 107) 2 108) 1 109) 1 110) 2
D) Fe(Steel) S) Self-reduction
111) 1 112) 3 113) 4 114) 2 115) 4
method
116) 3 117) 4 118) 2 119) 3 120) 2
PASSAGE
121) 1 122) 1 123) 3 124) 4 125) 3
Magnesium metal can also be obtained from
126) 4 127) 1 128) 1 129) 2 130) 2
magnesite. The magnesite mineral is calcined
131) 3 132) 1 133) 4 134) 1 135) 1
and the magnesia (MgO) thus obtained is
melted and electrolysed : In the commercial 136) 3 137) 4 138) 4 139) 4 140) 2
preparation, magnesia is mixed with the 141) 1 142) 2 143) 4 144) 2 145) 2
fluorides of Mg, Ba and Na in a steel tank at 146) 4 147) 2 148) 2 149) 3 150) 2
1170k to 1220k. A set of cast iron rods are 151) 2,3,4 152) 1,2,3 153) 1,2
projected from the bottom of the tank into the
NARAYANA SR. AIEEE MATERIAL 26 Metallurgy

154) 1,2,3,4 155) 1,2,3 156) 3 process

157) 3 158) 2 159) 1 27. Al2O3 cannot be reduced by carbon
160) A  Q,S B  R C  Q,R,S D  P
161) A  Q,R,S
28. 2NiO   CO  H 2   2Ni  CO2  H 2O
B  P,Q,R,S
29. Cu can be extracted by hydrometallurgy
C  Q,R 30.
D  P,Q,R 2 N a  A g  C N 2   Z n  N a 2  Z n  C N 4   2A g

162) 1 163) 2 164) 4 31. H 2 among H 2 , CO,C,Al is weakest

reducing agent
32. The process is called leaching
HINTS 33. Leaching is a step for metallurgy of Al
1. Au occurs in native state
2. Na is most Electropositive metal 34. Na  Ag  CN 2  is formed
3. Earthy impurities in minerals are called gangue 35. Electrorefining - purification of Crude Cu
4. Bauxite is the ore of Al 36. Zn - low M.P.
5. Na is extracted by Down's process 37. Pb has low M.P.
6. Least Electro positive metal is Au. 38. Ag is refined by cupellation
7. Cu 2O - Ruby Copper 39. Poling is used to refine metals having oxide
8. CaF2  Fluorospar impurity
9. AgCl-Horn Silver
40. Zn has low M.P. & B.P.
10. Argentite- Ag 2S
41. Cu - refined by poling
11. Willemite - Zn 2SiO 4
42. Ge - refined by zone refining
12. Calamine - Zn CO3
43. Cu 2S & CuFeS2
13. Carnallite  KCl.MgCl 2 .6H 2O
44. Cu 2S  little FeS  Matte
Dolomite  CaCO3.MgCO3
45. Cu lies below hydrogen in electrochemical
Asbestos  CaMg 3  SiO3 4 series
14. Bauxite- Al2O3 .2H 2O 46. FeO  SiO2  FeSiO3
Malachite  CuCO3.Cu  OH 2 47. Cu 2O is the impurity in blister Cu
15.
48. Zn - cannot occur in native state
Azurite  2CuCO3.Cu  OH 2
49. Zn is extracted by Belgian Process
16. Haematite is Concentrated by hand picking
17. Sulphide ores are concentrated by froth 50. Prolong is used in extraction of Zn

floatation process 51. Spelter - Impure Zn

18. The process is called calcination 52. In Belgian Process Producer gas is used as
19. Tinstone contains magnetic impurity fuel
wolframite
53. Magnetite - Fe3O 4
20. Olive oil is frothing agent 54. Cast Iron contains 4% carbon as impurity
21. Sodium ethyl xanthate acts as collecting
55. CaO  SiO 2  CaSiO3
agent
56. Pig Iron is formed in Blast furnace
22. Wolframite is the magnetic impurity
57. MacArthur - Forrest process - Ag
23. SiO 2  Quartz
24. Stibinite has low M.P 58. Metals above Cu in electrochemical series
25. CO is reducing agent for Fe 2O3 can be used for displacement
26. Extraction of metal from its ore is a reduction
NARAYANA SR. AIEEE MATERIAL 27 METALLURGY

59. Parke's process - For Argentiferous Lead 93. In Castner's process, Cathode is Fe rod.
60. Bauxite is the ore of Al 94. Ore has lower density in froth floatation process
61. Anhydride- CaSO 4 95. CaO is flux
62. Bauxite - Chief ore of Al
96. CaO  SiO 2  CaSiO3
63. Bauxite- Al2O3 .2H 2O 97. CO is blue gas
64. Al2O3 98. PbS  2PbO  3Pb  SO 2
65. Hoopes process- refining of Al
66. NaAlO 2 is formed 99. The process is called smelting
67. A l N, CO,Si vapours are formed
100 Cu 2S  2Cu 2O  6Cu  SO 2
68. Na 3AlF6 is used along with Al2O3
69. Electrolytic reduction as Al is highly
electropositive 101. Distillation method is used to obtained
70. Cryolite-Increases electrolytic conductivity
71. Al2O3`  Na 3AlF6  CaF2 ultrapure element.

72. Cryolite dissolves Al2O3 102. Zone refining

73. Pidgeon process is used to reduce MgO to
Mg 103. Copper is refined by electrolysis
74. Dolomite- MgCO3 .CaCO3
75. Carnallite- KCl.MgCl 2 .6H 2O 104. Cu 2S  little FeS  Matte
76. Dry HCl prevents hydrolysis of
105. Cu 2O - reduced by poling
MgCl 2 .2H 2O
77. Carnallite- KCl.MgCl 2 6H 2O 106. Blister Cu is produced by selfreduction in
78. Mg is obtained
Bessemers converter
79. Dry HCl is used to get anhydrous MgCl 2
107. Ore : Coke: limestone = 8:4:1
80. Mg is extracted from sea water

81. Li is diagonally related to Mg 108. CO 2  C  2CO

82. 2Mg  CO 2  2MgO  C 109. Wrought Iron is obtained by puddling process
Electrolysis
MgCl 2  Mg  Cl2 110. Slag - Ca 3 (PO 4 ) 2
83.
(cathode) (anode)
111. Thomas slag - Ca 3  PO4 2
84. Most abundant sodium salt in nature is NaCl
112. Quality is low for steel produced in Bessemer's
85. Chile salt petre - NaNO3 converter
86. KCl reduces the M.P. of NaCl 113. CO is main reducing agent
87. Free ions are present in molten NaCl 114. Carbon lining is cathode
115. Hoope's process- Refining of Al
88. Na is obtained in Down's process using fused
116. The reaction at Cathode is Al 3  3e   Al
NaCl as electrolyte
117. Baeyer's process is used for red bauxite and
89. Glauber's salt - Na2 SO4 . 10 H 2O
serpeck's process for white bauxite.
90. Oxone - Na2O2
91. Tincal - Na2 B4O7 . 10 H 2O 118. CaC2 is reducing agent
92. In Castner's process, Anode is Ni 119. Pidgeon process uses Fe-Si as reducing agent
NARAYANA SR. AIEEE MATERIAL 28 Metallurgy

120. Mg  H 2 O  MgO  H 2 146. (ii) Mg extracted by the electrolysis of fused

N
2  Mg N 
2  NH H O Mg Cl2
121. Mg  3 2 3
(iv) Red bauxite purified by Baeyers (or) Halls
2000 C
MgCl2 .6H 2 O 
 process
122.
MgCl2 .2H 2 O  4H 2O 147. (i) All ores are minerals but all minerals need
not be ores
123. Glauber's salt - Na2 SO4 . 10 H 2O
124. When M.P. is lower all options are applicable. (iv) Carnallite is KCl. MgCl2. 6H2O
125. 2Cl  Cl2  2e  at Anode 
  148. (iii) Roasting is for sulphide ores

126. Na at Cathode and Cl2 at Anode are

149. 2CuFeS2 + O2  Cu2S + 2FeS + SO2
produced in Down's process. 150. Reduction of Cu2O impurity in blister copper
 
127 2Cl  Cl2  2e reduced to copper by stirring with green poles.
(Loss of electron or oxidation) 151. All ores are minerals but all minerals need not
128. Bessemerisation is carried out for Fe, Cu be the ores
129. Zn, Cu, Pb occurs in ZnS, CuS, PbS forms 152. Leaching process is not suitable
130. Cassiterite - SnO2 153. By Roasting & Calcination ore becomes porous
Calamine – ZnCO3 155. Al metal can't be extracted by smelting
Rutile – Titanium ore 156. Zn is d-block non transition metal
Cerrusite – PbCO3 157. Sulphide ores are water insoluble
131. Near cathode : 2 H   2e   H 2 158. CuFeS2 is sulphide ore of copper and purified

Near anode : 4 OH

  2H O  O
2 2  4e  by froth floatation method
132. Adsorption principle 159. Due to less percentage of carbon wrought iron
133. Cupellation is used is more malleable and ductile than steel.
134. Cu2S + 2Cu2O  6Cu + SO2 160. Poling  Copper, Tin purified
135. Metal iodide is formed Cupellation  silver metal purified
136. Reversible reaction can be stopped by oxidizing Electro-refining  Copper, Silver, Tin are
Na2S to Na2SO4 in presence of stream of air purified
139. Au is less reactive than Ag Titanium purified by van Arkel method
140. Malachite is [Cu CO3.Cu(OH)2] 161. Pb  Roasting, Pyrometallurgy, Self-
141. Ellingham diagram represents the change of reduction method
G with temperature Cu  Bessemerisation, Roasting,
142. Ca is obtained by the electrolysis of CaCl2 Pyrometallurgy, Self-reduction method
fused Zn  Roasting, Pyrometallurgy
CaH2 + 2H2O  Ca(OH)2 + H2 Fe  Bessemerisation, Roasting,
143. a  when an oxide is decomposed to O2 gas Pyrometallurgy
and metal vapors, S increases 162. Mg CO3 MgO + CO2
b  decomposition requires energy 163. Mg + 2e–  Mg
+2

c  G  H  T S 164. MgO is mixed with fluorides of Mg, Ba, Na

144. X  Baeyers process, Y = SiO2
145. Reactivity of metals order is P > R > Q
* * *