The methods and separation of metals from their sources are discussed in this chapter. Metals are constantly extracted from their mineral sources. Mining is used to collect these ores, which are present in the earth's crust. The extraction and purification of metals is the subject of this chapter. This chapter describes a variety of procedures and processes that are specific to specific metals. This is a crucial chapter because it teaches you how these metals that you use every day are refined. The majority of naturally occurring components are classified as minerals, which contain metal compounds and are found in the earth's crust.
Ore is defined as a natural rock or silt containing one or more valuable minerals, primarily metal-bearing minerals, that may be extracted, processed, and sold for a profit. As a result, these ores may be thought of as minerals from which metal can be extracted cheaply and quickly. Metals are not usually present in their free state, and some metals, such as potassium, sodium, calcium, and magnesium, are found in a mixed state. General principles and processes of isolation of metals in chemistry aim to teach the students about the various processes of extraction of metals from ores. This article provides an example of the types of questions that might be asked about this subject in the JEE exam.
Principles of Metallurgy
Various refining methods
The earth's crust contains a large diversity of metals. Minerals are naturally occurring metallic compounds combined with sand, soil, and rocks that have a certain chemical makeup. Ore is a metallic compound with a reasonably high metal concentration that may be utilised to extract certain elements in a practical and cost-effective manner.
The definition of metallurgy is "the discipline of chemistry concerned with the extraction of metals in their pure state from their ore."
Native Ores: They contain the metal in the free state. Silver, gold, and platinum occur as native ores.
Oxidised Ores: They consist of oxides or oxysalts, such as carbonates, phosphates, sulphates, and silicates of metals.
Sulphurised Ores: They consist of sulphides of metals like iron, lead, zinc, and mercury.
Halide Ores: They consist of halides of metals.
The extraction process is used to reduce costs and to get the purest form of metal possible.
Metal extraction from ores must be made easier, better, and more cost-effective for the industry.
This is the method an extraction process is constructed, and it is based on the principles of metallurgy used to verify the inorganic chemical characteristics of the elements of ore.
Impurities such as pebbles, sands, and limestone are common in ore. It's called gangue. Flux is a chemical that is introduced to ore in order to eliminate the impurities that are there. The interaction of gangue and flux in ores then results in the creation of slag, a fusible substance.
The following principles are involved in metallurgy:
(1) Crushing and Grinding: This includes crushing ores into fine powder in a crusher, which is the basic process in metal metallurgy.
(2) The Concentration of Ores: The ores mined from the earth's crust contain a huge number of undesired impurities known as gangue, which include quartz, silicates, sand, feldspar, mica, and other minerals. The dressing is the process of removing undesirable contaminants from ore and is also known as the Concentration of ore because it steadily raises the amount of metal.
(3) Reduction to Free Metal: Reduction is the process of heating metal oxides to convert them to metal.
(4) Purification or Refining of the Metal: The resulting metal is processed using a variety of techniques.
It is referred to as the process of the removal of gangue from ore. There are a number of methods for the concentration of ores and the methods are based on the properties of the ore.
These methods are described below.
Hydraulic Washing: Ores are passed through an upward stream of water in this process, which separates the lighter gangue particles from the heavier metal ore. This is a gravity separation technique as well.
Magnetic Separation: The separation is carried out using the magnetic characteristics of either the ore or the gangue in this process. The ore is crushed into fine bits and then fed onto a conveyor belt that passes over a magnetic roller in this procedure. The magnetic ore stays on the belt, while the gangue falls off.
Froth Flotation Method: Gangue is discovered to be extracted from sulphide ores using this approach. The ore is first pulverised, after which it is suspended in water. Stabilisers are introduced to the collectors and froths. Pine oils, fatty acids, and other collectors improve the non-wettability of the metal component of the ore, allowing it to form a froth, while froth stabilisers (cresols, aniline, and other compounds) keep the froth in place. The oil used wets the metal, and the water wets the gangue even more. Paddles and air are used to continually stir up the suspension in order to generate the foam. In order to recover the metal, the frothy metal is scraped off the top and dried.
Calcination: It is a process that involves the heating of ore in the absence of air in order to remove water from hydrated oxide at temperatures below the melting point.
Roasting: It is a process that involves the roasting of ores to the temperatures below their melting points, that too mainly in the presence of air.
Leaching: When the ore is determined to be soluble in a solvent, this procedure is utilised. The powdered ore is subsequently dissolved in a chemical solution, most often a strong NaOH solution. The chemical solution dissolves the metal in the ore, and the chemical solution may be recovered and separated from the gangue. This method is used to extract aluminium from bauxite ore.
Smelting: Smelting is the process of removing metal in a state of fusion. The ore is combined with carbon derived from the preceding processes and heated in a suitable furnace in this procedure. During the procedure, a sufficient flux is supplied to convert the non-fusible gangue to fusible slag. The metal can be obtained in molten form or as condensed vapours when the metallic oxide is reduced by carbon. This method is used to extract metals such as tin, zinc, and lead.
Flux is a chemical used in the smelting process to transform infusible silicons or earthy impurities into slag, a fusible material. Slag is made up of impurities and flux. The slag has a low melting point and density and is incompatible with the metal. The slag floats on top of the metal, shielding it from oxidation. The slag hole is used to remove it from the furnace. If the impurities in the ore are acidic (SiO2), a basic flux, such as CaO, MgO, FeO, and so on, is added; if the impurities are basic (CaO, FeO, and so on), an acidic flux (SiO2) is utilised.
Goldschmidt Aluminothermic Process: When there are oxides that cannot be easily reduced by carbon, the reduction method is utilised. Metallic oxide ore is combined with aluminium powder, also known as thermite, and placed in a steel crucible lined inside with a refractory substance, which is then fired by a magnesium ribbon. A variety of metals, such as chromium and manganese, may be produced in a very pure condition on a commercial scale using this method.
Self-reduction Process: This procedure is also known as the auto reduction or air reduction procedure. Sulphide ores containing less electropositive metals such as Hg, Pb, Cu, and others are heated in air to convert a portion of the ore to oxide or sulphate, which interacts with the remaining sulphide ore to produce the metal and sulphur dioxide. In this procedure, no external reducing agent is utilised.
Electrolytic Reduction Process: Alkali and alkaline earth metals, zinc, and aluminium are all extracted using this method. The substance that will be used to make a metal is heated first and then electrolyzed. To reduce the melting point of the material consumed, some additional salt is sometimes added.
By Poling: Greenwood poles are used to stir the molten metals. Wood, when exposed to the high temperatures of molten metals, produces hydrocarbons such as methane, which is formed by the reduction of any oxide present in the metal, such as copper oxide in blister copper. In the instance of tin, the impurities oxidise and float as scum on the molten metal, which is then removed.
By Cupellation: When impurities are oxidised and blown away, the impure metal is heated in a blast of air. When impure silver is heated in the air, the lead in it oxidises to litharge (PbO) and is blown away, leaving a gleaming silver surface.
By Liquation: This method is used to refine easily flammable metals such as lead and tin. The impure metal is heated in a reverberatory furnace's sloping hearth. Impurities are left behind as the metal melts and flows down.
By Fractional Distillation: The separation of cadmium from zinc is done using this method. In zinc metallurgy, the metal is inextricably linked to cadmium. When the initial component of the condensate contains cadmium, the impure zinc is combined with powdered coke and heated, while zinc is produced in the succeeding sections.
Mond's Process: This process is used to purify nickel. The volatile chemical nickel carbonyl is generated when impure nickel is heated with carbon monoxide at 60–80°C. At 180°C, nickel carbonyl decomposes to pure nickel and carbon monoxide, which may be reused.
Van Arkel Process: This technique is commonly used to obtain ultrapure metals. The impurities are unaffected as the impure metal is transformed into a volatile chemical. The volatile molecule is subsequently electrically decomposed to provide pure metal. This process has been used to purify Ti, Zr, Hf, Si, and other materials.
Zone Refining or Fractional Crystallisation: This process refines semiconductor elements such as Si, Ge, Ga, and other similar elements. It is possible to acquire metals that are extremely pure. The approach relies on the difference in impurity solubility between the molten and solid states of metals. A moveable heater is wrapped around a metal rod. The heater is pushed across the rod carefully. The metal melts at the point of heating, and the pure metal crystallises as the heater advances from one end of the rod to the other, while the impurities pass through the neighbouring melted zone.
Example 1: Extraction of zinc from zinc blende is achieved by:
A. Electrolytic reduction
B. Roasting followed by reduction with carbon
C. Roasting followed by reduction with another metal
D. Roasting followed by self-reduction
Solution: Zinc is derived from zinc blende, which is a kind of mineral (ZnS). The ore is concentrated by using pine oil in the froth flotation process. The concentrated ore is next roasted at a high temperature of 1200K in the presence of air. Zinc sulphate (ZnSO4) is generated from a zinc blender when the roasting temperature is lower than this temperature. When the roasted ore is reduced by carbon, the zinc sulphate is transformed back to zinc sulphide. So, the correct option is B.
Key point to remember: Roasting is the process of heating sulphide ore to a high temperature in the presence of air or oxygen. It is an intermediate step in the processing of certain ores.
Example 2: Malachite is an ore of
Solution: The formation of malachite is by the weathering of copper ore bodies in the vicinity. The formula of Malachite is Cu2CO3(OH)2. So from the formula of Malachite, we can understand that it is an ore of copper.
Key point to remember: To know the formula of Malachite.
Question 1: Which of the following ores is concentrated by the chemical leaching method?
(c) Copper pyrites
Solution: In the metallurgy of silver, the respective metal is leached with a dilute solution of NaCN or KCN in the presence of air, which supplies O2. The metal is obtained later by replacement reaction.
Trick: Familiarity with the Leaching process.
Question 2: Which one of the following ores is best concentrated by the froth-flotation method?
Solution: Froth-floatation method: In this method, gangue is removed from sulphide ores. The ore is first powdered and its suspension is created in the water. To this collectors and froth, stabilisers are added. The oil wets the metal and the water wets the gangue. Paddles and air constantly stir up the suspension to create the froth. This frothy metal is skimmed off the top and dried, to recover the metal.
Since this method is used for the concentration of sulphide ores and here the only sulphide ore present is Galena (PbS). Therefore, option (3) is the answer.
Trick: To know the process of Froth-floatation.
Question 3: Common impurities present in bauxite are
Solution: Iron oxides such as hematite and goethite, Fe2O3, sand silicon dioxide SiO2, clay mineral kaolinite, and a minor quantity of TiO2 are all present in bauxite. So, the correct option is (d).
Trick: Iron oxides (goethite and hematite), silicon dioxide, the clay mineral kaolinite, and minor quantities of anatase are the most common impurities in bauxite.
Question 1: Sulphide ore is concentrated by:
(a) Froth flotation process
(b) Magnetic separation
(c) Gravity method
(d) Calcination method
Answer: (a) Froth flotation process.
Question 2: An ore of tin-containing FeCrO4 is concentrated by
(a) Gravity separation
(b) Magnetic separation
(c) Froth floatation
Answer: (b) Magnetic separation
Thus, the study of the extraction of metals from ores is important as it allows one to use the minerals present deep inside the earth's crust. A mineral is a naturally occurring mixture of metals and non-metals. Minerals can be used to extract metals. An ore is a naturally occurring solid substance from which precious metal or minerals may be extracted economically. Impurities or unwanted particles known as gangue pollute ore. Minerals are all ores, but the opposite is not true.
A variety of concepts are involved to carry out the extraction of various metals from their respective ores and further help in understanding a phenomenon in detail. Hence, this is important not only for competitive exams like JEE or NEET but also for a better understanding of the extraction process of metals.
1. What are the uses of aluminium, copper, zinc, and iron?
Aluminium is used for many things, including chocolate wrappers, power cables, paint, and the extraction of chromium and manganese.
Copper is utilised in the manufacture of electrical cables, steam pipes, and kitchen utensils. It's also used to manufacture brass and bronze alloys.
Batteries include zinc. It's used in dyes and paints as a reducing agent. It's also used to galvanise steel.
Iron is utilised in the production of steel, toys, pipes, and cutlery, among other things. Wrought iron is used to make wires, bolts, and chains, among other things.
2. What is the process of concentrating sulphide ore?
Only sulphide ores are concentrated by the froth flotation process because pine oil selectively wets the sulphide ore and hence brings it to the froth. The sulphide ores are preferably wetted by the oil and the gangue with the water.
3. What procedures are involved in extracting metals from their ore?
Various procedures involved are:
(i) Crushing and pulverisation
(ii) Concentration or dressing of the ore
(iii) Calcination or roasting of the ore
(iv) Reduction of metal oxides to free metal
(v) Purification and refining of metal are some of the common procedures involved in the extraction of metals from their ores