One Page Notes
ICSE Class 10
Metallurgy
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METALLURGY
(i) Occurrence of Metals in Nature
1. Mineral and Ore:
Mineral: Naturally occurring compounds from which metals can be extracted, but may not be economically viable.
Ore: A type of mineral that contains a metal in a sufficiently high concentration to make extraction economically feasible.
2. Common Ores:
Iron: Hematite (Fe₂O₃), Magnetite (Fe₃O₄)
Aluminium: Bauxite (Al₂O₃ · 2H₂O)
Zinc: Zinc Blende (ZnS), Calamine (ZnCO₃)
(ii) Stages Involved in the Extraction of Metals
(a) Dressing of the Ore:
Hydraulic Method: Uses water to separate ore from gangue (waste).
Magnetic Separation: Uses magnets to separate magnetic ores from non-magnetic gangue.
Froth Flotation Method: Uses chemicals to make ore particles float and separate from the gangue.
(b) Conversion of Concentrated Ore to Its Oxide:
Roasting: Heating the ore in the presence of oxygen to convert it to its oxide form.
Example: Roasting of Sulfide ores.
Equation: 2ZnS + 3O₂ → 2ZnO + 2SO₂
Calcination: Heating the ore in the absence of air to drive off volatile substances.
Example: Calcination of Carbonates.
Equation: CaCO₃ → CaO + CO₂
(c) Reduction of Metallic Oxides:
Reduction by Hydrogen:
Example: Reduction of Copper Oxide.
Equation: CuO + H₂ → Cu + H₂O
Reduction by Carbon:
Example: Reduction of Iron Oxide.
Equation: Fe₂O₃ + 3C → 2Fe + 3CO
Reduction by Carbon Monoxide:
Example: Reduction of Zinc Oxide.
Equation: ZnO + CO → Zn + CO₂
Some Metals (e.g., Al, Mg): Cannot be reduced by carbon; use electrolysis.
Active Metals: Sodium, Potassium, Calcium.
(d) Electrorefining: Reference only (used for purifying metals, involves electrolytic cells).
(iii) Extraction of Aluminium
(a) Purification of Bauxite (Baeyer’s Process):
Chemical Method:
Process: Bauxite is treated with sodium hydroxide to form sodium aluminate.
Equation: Al₂O₃ + 2NaOH + 3H₂O → 2Na[Al(OH)₄]
(b) Electrolytic Extraction (Hall-Héroult Process):
Structure of Electrolytic Cell:
Components:
Electrolyte: Alumina (Al₂O₃) dissolved in molten cryolite (Na₃AlF₆).
Electrodes:
Anode: Carbon rods.
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Cathode: Carbon-lined steel container.
Electrolytic Cell Description:
Anode Reaction: Oxidation of oxygen.
Equation: 2O²⁻ → O₂ + 4e⁻
Cathode Reaction: Reduction of aluminum.
Equation: Al³⁺ + 3e⁻ → Al
(iv) Alloys - Composition and Uses
1. Stainless Steel:
Composition: Iron, Chromium (Cr), Nickel (Ni).
Uses: Cutlery, surgical instruments, kitchen appliances.
2. Duralumin:
Composition: Aluminium, Copper (Cu), Manganese (Mn).
Uses: Aircraft structures, automotive parts.
3. Brass:
Composition: Copper (Cu), Zinc (Zn).
Uses: Musical instruments, plumbing fittings, coins.
4. Bronze:
Composition: Copper (Cu), Tin (Sn).
Uses: Statues, medals, bearings.
5. Fuse Metal / Solder:
Composition: Lead (Pb), Tin (Sn) for solder; various combinations for fuse metals.
Uses: Electrical connections (solder), safety fuses in electrical circuits.
Summary:
Metallurgy involves ore extraction and processing through methods like dressing, roasting, calcination, and reduction.
Aluminum is extracted via Bayer's and Hall-Héroult processes.
Alloys are designed for specific uses based on their composition.
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