Raahavy Balakumar

Extraction of Metal

Metals are often found in nature as ores, which are rocks containing sufficient minerals with high
concentrations of metal compounds. Hence an ore is a naturally occurring mineral from which a
metal can be extracted.

Metals have to be extracted from their ores through processes such as electrolysis, using
a blast furnace or by reacting with more reactive material.

Examples,

Common Ores Extraction Technique

Hematite (Fe₂O₃) for iron Heat oxide with carbon

Bauxite (Al₂O₃·2H₂O) for aluminum Electrolysis of oxide dissolved in molten cryolite

Copper pyrites (CuFeS2) for copper The sulfide ore is roasted in air

Rock salt (NaCl) for sodium Electrolysis of molten sodium chloride

Zince blende (ZnS) for zinc Sulfide is roasted in air and the oxide produced is
heated with carbon

Since unreactive metals are frequently found as the uncombined element, they do not need to be
removed chemically. This happens because of their chemical stability, which makes them difficult to
react with other chemicals. These are referred to as native metals, and two examples are platinum
and gold, which may be extracted straight from the crust of the Earth.

Metals which are very reactive, are extracted by electrolysis of their molten salts. This method
requires a large amount of energy due to the high reactivity and stability of their oxides.

In electrolysis, metal is produced at the cathode (negative electrode). A non-metal or other

substances are produced at the anode (positive electrode).

Carbon can be used to extract metals that are in the middle of the reactivity range, such as zinc
and iron. Carbon (in the form of coke or charcoal) is heated with the metal oxide (such as iron
oxide or zinc oxide).

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Extraction of Iron

Iron is primarily extracted from two main ores.

Ex : Hematite (Fe₂O₃)
Magnetite (Fe₃O₄)

These iron ore typically contain iron oxide and impurities such as Silicon dioxide (SiO2).

A blast furnace is used to extract iron from its ores,

Structure:

It is a tall, steel tower, typically about 50 meters high.

The interior is lined with heat-resistant bricks to withstand high temperatures.

Components:

• Charge: The furnace is loaded with a mixture of iron ore (hematite or magnetite), coke
(carbon derived from coal), and limestone (calcium carbonate).
• Hot Air: A blast of hot air is blown into the furnace near its base through openings called
tuyeres.

Operation:

• The carbon in the coke is oxidized by the heated hot air, producing a high temperature of
about 1500°C.
• The heat causes chemical reactions.

Cross-section of a blast furnace

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The raw materials: iron ore (hematite)

coke (an impure form of carbon)
limestone

They are added into the top of the blast furnace.

Later hot air is blown into the bottom.

Zone 1:

Coke burns in the hot air forming carbon dioxide

The reaction is exothermic so it gives off heat, heating the furnace.

C(s) + O2(g) → CO2(g)

Zone 2:

At the high temperatures in the furnace, more coke reacts with carbon dioxide forming carbon
monoxide (Carbon dioxide has been reduced to carbon monoxide). It is an endothermic reaction.

C(s) + CO2(g) → CO(g)

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Zone 3:

Carbon monoxide rises up in the furnace and reduces the iron (III) oxide in the iron ore to form iron
at a temperature of 700°C. This will melt and collect at the bottom of the furnace, where it is tapped
off.

Fe2O3(s) + 3CO(g) → 2Fe(l) + 3CO2(g)

Limestone (calcium carbonate) is added to the furnace to remove impurities in the ore.
The calcium carbonate in the limestone thermally decomposes to form calcium oxide.

CaCO3(s) → CaO(s) + CO2(g)

Impurities combine with calcium oxide to form slag (calcium silicate), which floats on top of the
molten iron due to its less density and is removed separately. CaO is alkaline in nature and reacts
with any acidic impurities (SiO2) present in the ore to form the slag.

CaO(s) + SiO2(s) → CaSiO3(l)

Molten iron accumulates at the bottom of the furnace and is periodically tapped off.

Basic Oxides: Metallic oxides like calcium oxide (CaO) are basic in nature.
Acidic Oxides: Non-metallic oxides such as silicon dioxide (SiO₂) are acidic.
Neutral and Amphoteric Oxides: Some oxides like carbon monoxide (CO) are neutral, while others
like zinc oxide (ZnO) can act as both acidic and basic (amphoteric).

Extraction Process:

• Tapping Off: Molten iron and molten slag are periodically tapped off (run off) from the
blast furnace.
• Waste Gases: Gases like nitrogen and carbon oxides escape from the top of the furnace.
These gases are used to heat incoming air through a heat exchange process, reducing energy
costs.
• Use of Slag: Slag, another waste material, is utilized by builders and road makers for
foundations.

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Metal Corrosion
Corrosion is the gradual destruction of metals by chemical reactions with their environment.

Factors Affecting Corrosion:

Moisture: Presence of water or moisture accelerates corrosion.

Oxygen: Availability of oxygen is necessary for oxidation, a key process in corrosion.
Acids: Acids can accelerate corrosion by reacting with metals.
Salts: Presence of salts (e.g., from sea water) can increase corrosion rates.

In general…
Corrosion refers to the gradual degradation or destruction of metals through chemical reactions with
their environment, which can include moisture, oxygen, acids, or salts.
Rust specifically refers to the corrosion of iron and its alloys (such as steel) when exposed to oxygen
and moisture. It is a type of corrosion that results in the formation of iron oxides, typically reddish-
brown in color.
Metals higher in the reactivity series corrode more rapidly when exposed to air or moisture.

Ex: Sodium and potassium are highly reactive metals that corrode rapidly in air if not
stored under oil or inert gases.

Metals like magnesium, calcium, and aluminium react with oxygen in the air to form a thin coating
of oxide.

Ex: Freshly produced copper is pink but turns brown due to the formation of copper (II)
oxide upon exposure to air.

Copper roofs and pipes in exposed environments develop verdigris, a green-colored patina. Verdigris
consists of copper salts, primarily copper (II) carbonate and copper(II) hydroxide [CuCO3.Cu(OH)2].
The exact composition of verdigris varies based on atmospheric conditions like humidity and
pollution levels.

Gold is a highly unreactive metal that does not corrode. It artifacts from ancient times remain intact
without corrosion, exemplifying its durability. Similar to gold, platinum exhibits high corrosion
resistance. It retains its luster and properties over extended periods, making it valuable for jewelry
and industrial applications.

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Rust

Rusting of iron and steel to form hydrated iron(II) oxide requires both water and oxygen. It is a
orange-red substance that forms on the surface of iron and its alloys (like steel) when they react
with oxygen and water. The process of rusting involves the following chemical reactions:
Iron + Oxygen + Water → Iron Oxide (Rust)

This reaction occurs when iron (Fe) reacts with oxygen (O₂) in the presence of moisture (water or
humidity). Rust forms a layer of iron oxide on the surface of the metal. It weakens the metal by
gradually eating away at it, causing it to flake and crumble.

Rust prevention

Preventing rust is essential to prolonging the lifespan and maintaining the appearance of metal
objects, tools, and equipment. Here are some effective ways to prevent rust by avoiding the metal
encountering air and water.

1. Painting
Metal can be protected by painting it with special paints or coatings. These create a
barrier that stops moisture from reaching the metal.
(If the paint on metal gets scratched, the iron underneath can begin to rust. Even if
the rest of the paint looks fine, corrosion can spread under the surface. That is why it
is crucial to maintain the paint in good condition and check it regularly).

2. Oiling and greasing

Application of oil/grease on moving parts act as a protective barrier and ensure
smooth operation of the machinery. Regular application helps maintain rust-free
metal tools and equipment.

3. Coating with plastic

Commonly used in household appliances and outdoor equipment exposed to
environmental conditions are applied exteriorly with plastic coatings, such as PVC
(Polyvinyl Chloride), which will act as the shield and will provide durable protection
from rust.

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4. Galvanization
Galvanizing involves coating the metal with a layer of zinc, which sacrificially corrodes
to protect the underlying metal. This method is commonly used for outdoor
structures like fences, gates, and utility poles. Even if the zinc layer is scratched, the
process continues, ensuring ongoing protection for the steel.

5. Sacrificial protection
The more reactive metal (sacrificial metal) corrodes preferentially, sacrificing itself to
protect the less reactive metal. This process occurs because the sacrificial metal
easily loses electrons, becoming ions in the electrolyte, while the less reactive metal
remains protected.

Sacrificial Protection with Zinc Bars: Zinc bars are attached to the hulls of ships and
oil rigs to prevent corrosion of the underlying
iron or steel structures.

Zn(s) + Fe2+(aq) → Zn2+(aq) + Fe(s) Zinc is more reactive than iron in the reactivity
series. When zinc and iron are in contact and
exposed to seawater or moisture, zinc
sacrificially corrodes instead of the iron.

Sacrifical protection with Gas and water pipes made of iron or steel are
Magnesium Blocks for Pipes : connected to blocks of magnesium to prevent
Corrosion.

Mg(s) + Fe2+(aq) → Mg2+(aq) + Fe(s) Magnesium is more reactive than iron and
steel, offering sacrificial protection against
corrosion. Similar to zinc, magnesium corrodes
preferentially by losing electrons to protect the
iron or steel pipes.

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Alloys
Materials that have at least one metal and two or more other elements together are called alloys.
They are created to improve the properties of metals for specific applications. They are beneficial
for many different applications because of their many distinctive qualities.

Properties Enhanced by Alloys:

• Alloys are often stronger and harder than pure metals.

• They can resist corrosion, wear, and high temperatures better than pure metals.
• Alloys can be tailored to have specific properties such as electrical conductivity, magnetism,
or biocompatibility.
• Alloys can provide similar or better performance than pure metals at a lower cost.

Alloys are usually stronger and harder than pure metals because the different metals mixed together
make it harder for the atoms to move around, so the alloy doesn't bend or break easily.

Alloys can resist things like rust and wear better than pure metals. For example, stainless steel
doesn't rust easily because it has a mix of metals that protect it from rust.

Pure metals Vs Alloys

Many alloys are harder or stronger than the pure metals they are made from. When metals with
different-sized atoms are mixed to form an alloy, the regular metal structure is disrupted. In pure
metals, atoms are arranged in layers that can slide over each other, making the metal malleable and
ductile (able to be shaped and stretched). However, in alloys with different-sized atoms, these layers
can't slide as easily. This makes alloys less malleable and ductile compared to pure metals.

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Alloys and Their Uses

Metals can be combined to create alloys, which have properties tailored for specific purposes.
Metallurgists have developed thousands of alloys, each designed for particular jobs. Below are
some common alloys and their uses:

Brass (Copper + Zinc)

o Uses: Musical instruments (trumpets), decorative items, plumbing fixtures.

Bronze (Copper + Tin)

o Uses: Statues, bells, bearings, tools.

Steel (Iron + Carbon + other elements like chromium, nickel)

o Uses: Construction (beams, reinforcement bars), manufacturing (machinery, tools),

automotive (car bodies, engines).

Stainless Steel (Iron + Chromium + Nickel)

o Uses: Kitchenware (sinks, cookware), architecture (building facades, bridges),

medical instruments (surgical tools, implants).

Aluminum Alloys (Aluminum + elements like copper, magnesium, silicon)

o Uses: Aerospace (aircraft frames, panels), automotive (engine blocks, wheels),

consumer electronics (laptops, smartphones).

Titanium Alloys (Titanium + elements like aluminum, vanadium, iron)

o Uses: Aerospace (jet engines, spacecraft components), medical implants (orthopedic

implants, dental implants), sports equipment (bicycle frames, golf clubs).

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