Chemistry

Metallurgy SESSION II
Session Opener

What is sterling silver?

Solid solution of Cu in Ag
Session Objectives
Session objectives

Methods of purification of metals

Metallurgy of Fe, Cu, Ag, Zn, Al

Refining of crude metal
1. Liquation process
Do you know?

Infusible impurity left over during liquation

is called as:

Dross
Refining of crude metal
2. Distillation:

Based on difference in
the boiling point of the
impurities and the
metal.
Volatile metals form
the vapour first and
separated by
condensing in a
receiver.
Refining of crude metal

3. Vacuum sublimation method

compressed crude metal

Metal under reduced pressure
in electric furnace

Molten metal Volatile impurities

(chilled to obtain pure
metal)
Refining of crude metal

4. Furnace refining or poling

Oxides are removed from impure metal

Re verbaratory furnace
Cu2O Cu SO2As2O3
Melted the metal

Reverbaratory furnace
Refining of crude metal

(5) Zone refining

Circular
heater
Recrystallized Impure
pure germanium germanium rod

Direction of trave of
Molten zone
heater, molten zonel
(containing
and impurities
impurities)
Refining of crude metal

6. Van Arkel method (or Vapour phase refining)

250C
Ti 2l2
Til4
Ti tanium
tetraiodide

1400C
Til4 Ti 2 l2
Tungsten
filament
Refining of crude metal

7. Thermal decomposition
method (Carbonyl
method, Mond Process)

Ni 4CO
Ni(CO)4
Ni 4CO
Impure Nickel Pure
nickel tetracarbonyl Nickle
Refining of crude metal
8. Cupellation
Used for purification of silver containing
impurity of lead.
Based on selective oxidation of lead over
silver.
The impure silver is smelted in cupel
(dish made of bone ash) in blast of air in
reverberatory furnace.
Lead is oxidised to lead oxide (PbO) and
blown away by blast of air.
The remaining part melts and is
absorbed by the bone ash cupel. At the
end cupel is covered by silver.
Refining of crude metal

9. Electrolytic refining
Electrolytic refining

10. Chromatographic
method:
Based on the difference in the
adsorbability of the metal and
the impurities.
Adsorbentalumina (Al2O3).
Eleuent
Specifically useful for the
separation of the elements
available in very
small amounts.
Ellingham diagram
Metallurgy of Iron
(i) Ore
Haematite (Fe2O3)

(ii) Concentration of ore

by magnetic separation

(iii) Roasting
Moisture, sands are removed as oxide.

(iv)Smelting
Done in blast furnace.
Roasted ore, limestone and coke are added in
blast furnace for smelting.
Metallurgy of Iron
Fe2 O3 + C+CaCO3

Fe2O3 +CO 2FeO+CO2

Fe3O4 + CO 3FeO+CO2
FeO+CO Fe+CO2
Waste
Zone of reduction 575 - 975 K
Gases
Central Zone 1175 - 1475 K
CaCO3 CaO CO2
CaO SiO2 CaSiO3
Flux Impurity Slag 1475 - 1575 K

Zone of fusion

Zone of combustion 1775 - 1800 K

Steel shell
C O2 CO2 415 kJ
CO2 C 2CO 162.3 kJ

Hot air blast

through thyeres

Slag
Molten iron
Heat treatment of steel
1. Quenching or hardening
Process of heating steel
to red hot followed by sudden
cooling by plunging to oil or
water.
Makes steel hard and
brittle due to formation of
iron carbide (Fe3C).
2. Annealing
Process of heating steel to
red hot then cooling slowly.
Annealing makes steel soft and
ductile.
Heat treatment of steel
3. Tempering
Process of heating steel the
quenched steel to temperature much
below redness followed by slow cooling.
Tempering retains the hardness but
brittleness disappears.

4. Nitriding
Process of producing hard coating or iron nitride on
surface of steel.
Metallurgy of copper

1. Ore Copper pyrite CuFeS2

2. Concentration Froth floatation process.
3. Roasting

2CuFeS2 O2 Cu2 S 2FeS SO2

2Cu2 S 3O2 2Cu2 O 2SO2 (Partly)
2FeS 3O2 2FeO 2SO2 (Partly)
Metallurgy of copper
Smelting

FeO SiO2 FeSiO3

Slag

Since iron has more affinity for oxygen,

therefore FeO is formed first.

Cu2 O FeS Cu2 S FeO

Slag is removed from upper layer. Molten mass
containing Cu2S and Fe is called copper malte.
Metallurgy of copper
Basemerisation
Molten matter is mixed with
sand (SiO2) and heated in
Basemer converter.
2FeS 3O2 2FeO 2SO2
FeO SiO2 FeSiO3
Slag

2Cu2 S 3O2 2Cu2 O 2SO2

2Cu2 O Cu2 S 6Cu SO2

Blister copper.

Refining of copper
By poling of electrolytic refining.
What is matte?

(a) CuO + FeS

(b) CuS + FeO

(c) Cu2S + FeS

(d) None of the above

Metallurgy of Silver
1. Ore
Argentite AgS
2. Concentration
By froth flotation process.
3. Extraction
By Mac Arthur Forrest Process.

Ag2 S 4NaCN 2Na Ag(CN)2 Na2 S

Sodium
arg entocyanide
(water so lub le)
2Na Ag(CN)2 Zn Na2 Zn(CN)4 2Ag

4. Refining
By electrolytic method.
Illustrative example

Name the metals which are

consumed in elemental form?

Metals consumed in elemental form are Ag and Au.

Metallurgy of Zinc
1. Ore
Zinc blende (ZnS)
2. Concentration of ore
By froth flotation process.
3. Roasting
2ZnS 3O2 2ZnO 2SO2
4. Conversion of ZnO to Zn
distillation
ZnO C Zn CO

Vapours of Zn of are collected after distillation.

Illustrative example
Spelter is

(a) 98% Zinc

(b) Pure Zinc

(c) 98% Al

(d) Impure Fe
Metallurgy of Aluminium

1. Ore
Bauxite Al2O3
2. Concentration of bauxite
The method of concentration of bauxite
depends on nature of impurity present in it.
Baeyers process
Used when impurity is of ferrous oxide.
Baeyers process

Al2O3 2NaOH
2NaAlO2 H2 O

NaAlO2 2H2O
Al(OH)3 NaOH
(White ppt)

2Al(OH)3
Al2O3 3H2O
(Pure)
Serpecks process

Used when silica is the chief impurity in bauxite.

D
Impure + C + N2 AlN + Silicone (volatile)
Bauxite Aluminium
nitride

+ H2O
D

Al(OH)3
(ppt)

Pure Al2O3
Serpecks process

Al2 O3 3C N2
2AlN 3CO
Alu minium
nitride

2Al(OH)3
Al2O3 3H2O
(Pure)

AlN 3H2O
Al(OH)3 NH3
(Pr ecipitate)
Halls Process
Used when no specific type of impurity is present.
Insoluble impurities (Fe2O3 and others)
Na2CO3
Impure
Bauxite
Filtered Soluble sodium meta-aluminate

H2O and filtered

Al(OH)3 NaOH
Precipitate Solution

Pure Al2O3
Hopps process

+
Impure aluminium

Pure aluminium (cathode) Iron tank having

lining of graphite
Cryolyte + BaF2 (electrolyte)

Impure Al (Anode)

Hopp's process
Electrolysis of pure alumina (Al2O3)
Na3 AlF6 3NaF AlF3
AlF3 Al3 3F

At cathode 2Al3 6e 2Al

3
At anode Al2 O3 6F 2AlF3 O2 6e
2
Question
Thank you