Extraction of

metals
Only some unreactive metals such
as silver, gold and platinum can
occur freely in nature. Most metals
react with other elements to form
ores.
 Major steps in extraction of metal
Ore concentration
Ore is purified and concentrated, unwanted
rocks removed
Reduction to crude metal
Metal oxides to be reduced to metals, resulting
in a mixture of metals collected
Refining to obtain pure metal
To obtain a specific metal, purify and remove
unwanted metal impurities
 the extraction of metals
Method of extraction depends on the position of the metal in
the reactivity series.
extraction of metal involves:
o getting rid of the unwanted rock to obtain concentrated
form of the mineral
o obtaining pure metal from the mineral by chemical
reactions
 the extraction of metals
Metals at the top of the reactivity series are very reactive:
bonds in their compounds are very strong
must be extracted by decomposing their compounds with
electricity in an expensive process called electrolysis
aluminium is extracted from aluminium oxide by passing an
electric current through it

2Al2O3 4Al + 3O2

 Ways of Extraction
Potassium K
Extracted by
Sodium Na
electrolysis of
Calcium Ca
molten chlorides
Magnesium Mg
Extraction by Aluminium Al
electrolysis of Zinc Zn
molten Al2O3 Iron Fe Extraction by
dissolved in Tin Sn reduction of
cryolite Lead Pb oxides using
Copper Cu carbon
Mercury Hg
Silver Ag
Roasting ore by
Gold Au
heating alone
Platinum Pt
Extraction of Iron
Raw materials of extraction of Iron
Iron Ore
eg haematite ore [iron(III) oxide,
Fe2O3]
Coke
carbon, C
Hot air
for the O2 in it
Limestone
calcium carbonate, CaCO3
 Stage 1 Production of carbon
dioxide
Thecoke is ignited at the base and hot air
blown in to burn the coke (carbon) to form
carbon dioxide
C(s) + O2(g) CO2(g)
Thelimestone is decomposed by heat to
produce carbon dioxide & quicklime
CaCO3(s) CaO(s) + CO2(g)
 Stage 2 Production of carbon
monoxide
Athigh temperature, the carbon dioxide
formed reacts with more coke (carbon) to form
carbon monoxide
CO2(g) + C(s) 2CO(g)
 Stage 3 Reduction of haematite
The carbon monoxide removes the oxygen
from the iron oxide ore.
This frees the iron, which is molten at the high
blast furnace temperature, and flows down to
the base of the blast furnace.
Fe2O3(s) + 3CO(g) 2Fe(l) + 3CO2(g)
Other possible ore reduction reactions are ...
Fe2O3(s) + 3C(s) 2Fe(l) + 3CO(g)
2Fe2O3 (s) + 3C(s) 4Fe(l) + 3CO2 (g)
 Stage 3 Reduction of haematite
Waste gases escape through the top of the
furnace
Eg. Carbon monoxide, carbon dioxide,
nitrogen
Stage 4 Removal of Impurities
The original ore contains silica (SiO2, silicon
dioxide). These react with limestone to form a molten
slag of e.g. calcium silicate in 2 stages
CaCO3 CaO + CO2
CaO + SiO2 CaSiO3
The molten slag forms a layer above the more dense
molten iron and can be separately, and regularly,
drained away. The iron is cooled and cast into pig
iron ingots / transferred directly to a steel producing
furnace
Slag can be used for road surfacing
http://www.bbc.co.uk/history/games/blast/blast.shtml
 Why Steel?
Steel is iron that has most of the
impurities removed. Steel also has a
consistent concentration of carbon
throughout (0.5 percent to 1.5 percent)
Impurities like silica, phosphorous and
sulphur weaken steel tremendously, so
they must be eliminated
The advantage of steel over iron is greatly
improved strength
 Pig Iron to Steel Using Basic
Oxygen Furnace
Pear-shaped furnace, lined with refractory
bricks, that refines molten iron from the
blast furnace and scrap into steel
Scrap is dumped into the furnace vessel
Followed by the hot metal from the blast
furnace.
A high-pressure stream of oxygen is blown
into it to cause chemical reactions that
separate impurities as fumes or slag
Once refined, the liquid steel and slag are
poured into separate containers
 Types of Steel
Steel Percentage of carbon

Mild carbon steel Up to 0.25%

High carbon steel 0.45% - 1.50%

Stainless steel alloy Little carbon, with

chromium & nickel
 Properties of Steel
Can be changed by the use of
controlled additives
Eg. Carbon, chromium, nickel,
manganese, silicon etc
 Uses of Steel
Steel Uses
Mild carbon steel Make steel parts in
strong, hard & car bodies ,
malleable machineries
High carbon steel Make knives,
strong but brittle hammer, cutting
tools
Stainless steel Pipes & tanks in
does not rust chemical plants,
making cutlery,
surgical instruments
 Alloy
Mixture of a metal with other
elements
Element in the largest proportion is
the base metal
Elements in smaller proportions are
the alloying elements
 Metals
Soft

Low resistance to corrosion

High m.p

Easy to shape
 Alloys
Have different physical properties
compared to their constituent
elements
Produce mainly for:
Improving strength and hardness
Improving resistance towards corrosion
Improving appearance of metal
Lower m.p of metal
 Extraction of Aluminium from
Bauxite
Raw materials
Bauxite: ore containing hydrated aluminium
oxide Al2O3.2H2O
M.p: ~2000C

Molten Cryolite aka sodium aluminium fluoride

Na3AlF6
used to lower m.p to ~900C

Carbon electrodes
http://www.patana.ac.th/parents/curriculu
m/Chemistry/units/LR803.html
 Extraction of Aluminium
Cryolite is added to lower the melting
point & to dissolve the ore & bauxite
ore of aluminium oxide is
continuously added
When p.d is applied,
Al3+ is attracted to the negative cathode
O2- is attracted to the positive anode
 Extraction of Aluminium
At the cathode,
Al3+ gains 3 electrons from the cathode to
form molten aluminium, which is tapped off
Al3+(l) + 3e- Al (l)
At the anode,
O2- loses 2 electrons to the anode to form
oxygen
2O2-(l) O2(g) + 4e-
Oxygen released attacks carbon anode, to
form Carbon monoxide/dioxide. Carbon anode
dissolved. Needs to be replaced regularly
 Anodising
Form of electroplating using oxygen,
used commonly for aluminium
Aluminium when exposed in air
forms a thin protective coat of
aluminium oxide
For better protection, a thicker coat
is made
Through the process: Anodising
 Anodising
Make aluminium the anode in sulphuric
acid bath
Oxygen produced at the anode then
combines with aluminium to form a
protective porous layer aluminium oxide
1000 times thicker, compared when
exposed to air
Pores can be sealed by dipping into hot
water or coloured by using dyes which can
be absorbed into it
 Uses of Aluminium
Uses Properties
Overhead Low density, light
electric cables Resistant to corrosion
(protected by aluminium oxide)
Good electrical conductivity
Food containers Non-toxic
Resistant to corrosion
Good conductor of heat

Aircraft body Low density, light

High tensile strength
Resistant to corrosion
 Conditions for
Corrosion of Iron
Presence of oxygen
Presence of water

Presence of sodium
chloride/acidic pollutants
speed up rusting

4Fe(s) + 3O (g) +
Rusting is an exothermic
2

redox reaction where iron

2xH O(l)
is oxidized to form
2
hydrated iron(III) oxide
2Fe2O3.xH2O (s)
 Prevention of rusting
Use of protective layer
Painting Used in cars, ships,
bridges
Greasing Tools & machine parts
Zinc plating(Galvanising) Zinc
roofs
Tin plating Food cans
Creates barrier around the metal
preventing contact with oxygen
and water
 Sacrificial protection
More reactive metal, eg, Magnesium
or zinc is attached to iron or steel
Protects by sacrificing itself, corrodes
first since it is more reactive
Iron will not rust in the presence of a
more reactive metal
Used in underground pipes, ships,
steel piers
 Alloying
Addition of nickel and chromium to
iron
Chromium (III) oxide Cr2O3 on the
surface protects iron from corrosion
Used in cutlery, surgical instruments,
pipes & tanks in chemical plants
 Finite Resource
Metal ores finite resource, will be
used up
Need to recycle metals

Save resources and solves litter

disposal
Saves energy

Saves costs