Metallurgy

ICSE Class 10 Chemistry • Chapter 07

1. Basic Terminology

Term Definition
Mineral Naturally occurring compound of metal found in earth's crust
Ore Mineral from which metal can be extracted profitably
Gangue Earthy impurities associated with ore
Metallurgy Process of extracting metal from its ore

2. Common Ores

Metal Ore Name Formula
Iron Haematite Fe₂O₃
Magnetite Fe₃O₄
Aluminium Bauxite Al₂O₃·2H₂O
Zinc Zinc blende ZnS
Calamine ZnCO₃
Copper Copper pyrites CuFeS₂

3. Activity Series of Metals

Decreasing reactivity (top to bottom):

K > Na > Ca > Mg > Al > Zn > Fe > Pb > H > Cu > Hg > Ag > Au

Memory: "Please Send Charlie's Monkey After Zebras In Large Parks Harbouring Cute Harmless Silver Goldfish"

Extraction Method Based on Activity Series:

4. Steps in Extraction of Metals

Step 1: Concentration (Dressing) of Ore

Method Used For Principle
Hydraulic Washing Heavy ores Difference in density
Magnetic Separation Magnetic ores (Fe₃O₄) Magnetic property
Froth Flotation Sulphide ores Preferential wetting

Step 2: Conversion to Oxide

Calcination: Heating ore in absence of air (for carbonates)

$ZnCO_3 \xrightarrow{\Delta} ZnO + CO_2$

Roasting: Heating ore in presence of air (for sulphides)

$2ZnS + 3O_2 \xrightarrow{\Delta} 2ZnO + 2SO_2$

Step 3: Reduction to Metal

Reduction with Carbon:

$ZnO + C \xrightarrow{\Delta} Zn + CO$

$Fe_2O_3 + 3CO \xrightarrow{\Delta} 2Fe + 3CO_2$

Electrolytic Reduction: For highly reactive metals (Al)

Step 4: Refining

Purification of metal (e.g., electro-refining for copper)

5. Extraction of Aluminium (Hall-Héroult Process)

Ore: Bauxite (Al₂O₃·2H₂O)

Step 1 - Bayer's Process: Purification of bauxite to pure Al₂O₃

Al₂O₃ + 2NaOH → 2NaAlO₂ + H₂O (dissolution)

NaAlO₂ + 2H₂O → Al(OH)₃ + NaOH (precipitation)

2Al(OH)₃ → Al₂O₃ + 3H₂O (calcination)

Electrolysis of Molten Al₂O₃:

Electrolyte: Al₂O₃ dissolved in molten cryolite (Na₃AlF₆)

Why cryolite? Lowers melting point from 2050°C to 950°C

Cathode: Carbon-lined steel tank

Anode: Graphite rods

At Cathode: Al³⁺ + 3e⁻ → Al

At Anode: 2O²⁻ → O₂ + 4e⁻

Note: Anode gets oxidised by O₂ and needs periodic replacement.

6. Alloys

Alloy: A homogeneous mixture of two or more metals, or a metal with non-metal.

Purpose: To improve properties like hardness, strength, corrosion resistance.

Alloy Composition Uses
Brass Cu + Zn Utensils, decorative items
Bronze Cu + Sn Statues, medals, coins
Stainless Steel Fe + C + Cr + Ni Surgical instruments, kitchenware
Solder Pb + Sn Joining electrical wires
Duralumin Al + Cu + Mg + Mn Aircraft bodies
Fuse Metal Bi + Pb + Sn Electric fuses

Quick Reference

Metal Activity Extraction Method Example
High (K, Na, Ca, Mg, Al) Electrolysis Al from Al₂O₃
Medium (Zn, Fe, Pb) Reduction with C/CO Fe from Fe₂O₃
Low (Cu, Hg, Ag) Roasting/Heating Hg from HgS

Exam Practice (PYQ Trends)

PYQ: 2023

BOARD Why is cryolite added during extraction of aluminium? Give electrode reactions.

PYQ: 2022

BOARD Distinguish between calcination and roasting with equations.