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Principles of Metallurgy: P. Nagaraja
Principles of Metallurgy: P. Nagaraja
Principles of Metallurgy: P. Nagaraja
P. Nagaraja
Assistant Professor in Chemistry
IIIT, RK VALLEY
Introduction
metal compound
metal
06/08/2022 P Nagaraja, Asst. Prof. in Chemistry, IIIT RKV 9
Principles of extraction
The extraction and isolation of metals from ores involves the following steps
The metal oxide on heating with a reducing agent such as coke (C) or carbon
monoxide (CO) or H2 gas forms the corresponding metal.
4. Refining of metal
The process of obtaining a highly pure metal from impure metal is known as
refining.
06/08/2022 P Nagaraja, Asst. Prof. in Chemistry, IIIT RKV 10
Concentration of the ore
Ores may be concentrated by several methods which depend
upon the nature of ore and impurities present in it.
The different methods of dressing are discussed below
1. Hydraulic washing or gravity separation
Principle: This method is based in the differences in
gravities of the ore and gangue particles.
Al2O3 + NaOH
• Examples:
• Carbonates decomposes with evolution of CO2
ZnCO3 → ZnO + CO2
CaCO3 → CaO + CO2
• Hydrated ores looses water on calcination
Al2O3.2H2O → Al2O3 + 2H2O
Fe2O3.3H2O → Fe2O3 + 3H2O
S + O2 → SO2 ↑
2 As + 3 O2 → As2O3
06/08/2022 P Nagaraja, Asst. Prof. in Chemistry, IIIT RKV 16
Reduction of oxide ore
• Smelting: The reduction of roasted ore with coke and flux in
the presence of air at high temperatures is called smelting.
• The metal oxide on heating with a reducing agent such as
coke (C) or carbon monoxide (CO) or H2 gas forms the
corresponding metal.
• In this process, roasted ore is reduced to metal and impurities
present are removed as slag
• The selection of reducing agent usually depends on chemical
reactivity of the metal.
Zone of combustion
C + O2 → CO2
Zone of reduction
CO2 + C → 2CO
Fe2O3 + 3CO → 2Fe + 3CO2
S + O2 → SO2
2. Roasting 2 As + 3 O2 → As2O3
2CuFeS2 + O2 → Cu2S + 2FeS + SO2
1. Concentration of ore
2. Roasting
3. Smelting (reduction)
4. Refining of zinc
S + O2 → SO2
2. Roasting
2 As + 3 O2 → As2O3
2 ZnS + 3 O2 → 2 ZnO + 2 SO2
3. Smelting
ZnO + C → Zn + CO
(reduction)
1. Concentration of ore
2. Roasting
3. Smelting
4. Making of pig iron
Zone of combustion
C + O2 → CO2
Zone of reduction
CO2 + C → 2CO
Fe2O3 + 3CO → 2Fe + 3CO2
Ionization of Alumina
Al2O3(aq) → 2Al3+(aq) + 3O2-(aq)
At anode: 2O2- → O + 4 e-
2(g)
400-700oC
800-1000oC
1600oC
Slag
The electrolysis is carried out in a carbon lined iron tank, which is filled with
three molten layers of different specific gravity one over the other.
Top layer: Pure molten Al - Cathode
Middle layer: (Na3 AlF6 + Ba F2) – electrolyte
Bottom layer: Impure Aluminum - Anode
When electric current is passed, Al+3 ions from the middle layer go to the top
layer and are deposited as pure Aluminium.
06/08/2022 P Nagaraja, Asst. Prof. in Chemistry, IIIT RKV 63
Magnesium
• Magnesium occurs as
• Magnesite-MgCO3
• Dolomite- MgCO3.CaCO3
• Epsomite- MgSO4.7H2O
• Carnalite- 2KCl.MgCl2.6H2O etc.,
• The chloride and sulfate ores are available in
sea water which is being extracted