12th STD Unit-1,2,6
12th STD Unit-1,2,6
METALLURGY
1. What are the difference between minerals and ores?
Minerals Ores
A naturally occurring substance obtained by Minerals that contain a high percentage of metal,
mining which contains the metal in free state or from which it can be extracted conveniently and
in the form of compounds like oxides, sulphides economically are called ores.
etc… is called a mineral.
All minerals are not ores . All ores are minerals.
Contains less percentage of metal Contains high percentage of metal
China clay and Bauxite are minerals of Al. Bauxite is the ore of Al.
2. What are the various steps involved in extraction of pure metals from their ores?
Concentration of the ore.
Extraction of crude metal.
Refining of crude metal.
3. What is the role of Limestone in the extraction of Iron from its oxide Fe2 O3?
A limestone (CaO) is used as a basic flux, in the extraction of iron from its oxide Fe 2O3.
The silica gangue present in the ore is acidic in nature, the limestone combines with it to form
Calcium silicate (slag)
CaO(s)+ SiO2(s) → CaSiO3(s)
Flux Gangue Slag
4. Which type of ores can be concentrated by froth floatation method? Give two examples for such ores.
Sulphide ores are concentrated by froth floatation method.
Eg : galena (PbS), zinc blende (ZnS)
5. Describe a method for refining nickel.
Nickel is refined by Mond process.
Impure nickel is heated with carbon monoxide at 350K to form a highly volatile nickel tetracarbonyl.
Ni(s) + 4CO(g) [Ni(CO)4](g)
When Nickel tetra carbonyl is heated at 460K, it decomposes to give pure nickel.
[Ni(CO)4](g) Ni(s) + 4CO(g)
6. Explain zone refining process with an example.
This method is based on Fractional Crystallisation
When an impure metal is melted and allowed to solidify, the impurities will prefer to be in the molten
region.
The impure metal is taken in the form of a rod
When the metal rod is heated with a heater, the metal melts.
The heater is slowly moved from one end to the other end.
The impurity dissolves in the molten zone. The pure metal will crystallize.
When the heater moves the molten zone also moves.
This process is repeated again and again to get the pure metal.
This process is carried out in an inert gas atmosphere to prevent the oxidation of metals.
E.g. Germanium, Silicon and Gallium which are used as semiconductor are refined by this process.
7.Using the Ellingham diagram,
(A) Predict the conditions under which
(i) Aluminium might be expected to reduce magnesia.
(ii) Magnesium could reduce alumina.
(B) it is possible to reduce Fe2O3 by coke at a temperature around 1200K
(A) (i) Ellingham diagram for the formation of Al 2O3 and MgO intersects around 1600K. Above this
Temperature Al line lies below the Mg line. Hence we can use Al to reduce Magnesia above 1600K.
(ii) In Ellingham diagram below 1600K Mg line lies below Al line. Hence below 1600K Mg can
reduce alumina.
(B) In Ellingham diagram above 1000K carbon line lies below the iron line. Hence it is possible to reduce
Fe2O3 by coke at a temperature around 1200K.
8. Give the uses of zinc.
Metallic zinc is used in galvanizing of iron and steel to protect them from rusting and corrosion.
Used to produce die-castings in the automobile, electrical and hardware industries.
Zinc oxide is used in the manufacture of paints, rubber, cosmetics, pharmaceuticals, plastics, inks,
batteries, textiles and electrical equipment.
Zinc sulphide is used in making luminous paints, fluorescent lights and x-ray screens.
9. Explain the electrometallurgy of aluminium.
Aluminium is extracted by Hall – Herold process
Cathode :- Iron tank coated with Carbon
Anode: - Carbon rod
Electrolyte :- Calcium Chloride + Alumina + Cryolite
Temperature :- 1270K
Pure Aluminium is deposited at the cathode
Ionization of aluminia: Al2O3 → 2Al3+ + 3O2-
Reaction At cathode :- 2Al3+(aq) + 6e- → 2Al(l)
Reaction At anode :- 6O2- → 3O2 + 12e-
Reaction in Carbon rod :-
C(s) + O2-(aq) → CO + 2 e-
C(s) + 2O2-(aq) → CO2 + 4 e-
During the above reaction carbon is slowly consumed.
The pure aluminium is formed at the cathode and settles at the bottom.
The net electrolysis reaction can be written as follows
4Al3+(melt) + 6O2–(melt) + 3C(s) 4Al(l) + 3CO2(g)
10.Explain the following terms with suitable examples.
(i) Gangue (ii) Slag
(i) Gangue
The nonmetallic impurities, rocky materials and siliceous matter which are associated with the ore
Which are collectively known as gangue.
Eg : Aluminosilicate is the gangue present in gold ore.
(ii) Slag
Slag is fusible product, which is formed by the reaction of gangue with a flux.
Eg : CaO + SiO2 CaSiO3
(flux) (gangue) (slag)
11. Give the basic requirement for vapour phase refining.
The two requirements are
The impure metal should form a volatile compound with suitable reagent.
The volatile compound should be easily decomposed to give the pure metal.
12. Describe the role of the following in the process mentioned.
(i) Silica in the extraction of copper.
(ii) Cryolite in the extraction of aluminium.
(iii) Iodine in the refining of Zirconium.
(iv) Sodium cyanide in froth floatation.
(i) Silica in the extraction of copper.
In the extraction of copper silica acts as an acidic flux to combine gangue FeO to form slag FeSiO3.
FeO + SiO2 FeSiO3
(ii) Cryolite in the extraction of aluminium.
As Al2O3 is a poor conductor, cryolite improve the electrical conductivity. Cryolite lowers the melting point
of the electrolyte.
(iii) Iodine in the refining of Zirconium.
Iodine is the suitable reagent in the purification of Zr.
Zr(s) (impure) + 2I2 → ZrI4 ( vapour )
ZrI4 ( vapour ) → Zr(s) (pure) + 2I2
(iv). Sodium cyanide in froth floatation.
In froth floatation process, sodium cyanide is used as a depressing agent. It selectively prevents other metal
sulphides from coming to the froth.
Eg : ZnS is present as impurity in galena (PbS)
13. Explain the principle of electrolytic refining with an example.
Crude metal is refined by electrolysis. It is carried out in an electrolytic cell.
Cathode: Thin strips of pure metal.
Anode: Impure metal to be refined.
Electrolyte: Aqueous salt solution of the metal with dil. Acid.
As current is passed, the metal of interest dissolved from the anode and pass into electrolytic solution.
At the same time same amount of metal ions from solution will be deposited at the cathode.
Less electro positive impurities in the anode settle down as anode mud.
Example : Electro refining of silver.
Cathode: pure silver
Anode: impure silver rods.
Electrolyte: Acidified aqueous solution of silver nitrate.
When current passed, the following reaction takes place.
Reaction at anode : Ag(s) → Ag+ + e–
Reaction at cathode : Ag+ + e– → Ag(s)
14. The selection of reducing agent depends on the thermodynamic factor: Explain with an example.
A suitable reducing agent is selected based on the thermodynamic considerations.
For a spontaneous reaction, the change in free energy should be negative.
Thermodynamically, the reduction of metal oxide with a given reducing agent can occur if the free
energy change for the coupled reaction is negative.
Hence, the reducing agent is selected in such a way that it provides a large negative ΔG value for the
coupled reaction.
Eg : Reduction of ZnO by carbon monoxide.
ZnO + CO Zn + CO2 ΔG° = +ve (non spontaneous)
Reduction of ZnO by coke
ZnO + C Zn + CO ΔG° = –ve (spontaneous)
So, coke is better reducing agent for the reduction of ZnO into Zn.
15. Give the limitations of Ellingham diagram.
Ellingham diagram is constructed based only on thermodynamic considerations.
It gives information about the thermodynamic feasibility of a reaction. It does not tell anything about
the rate of the reaction.
It does not give any idea about the possibility of other reactions that might be taking place.
The interpretation of ΔG is based on the assumption that the reactants are in equilibrium with the
products which is not always true.
16. Write a short note on electrochemical principles of metallurgy.
The reduction of oxides of active metals such as sodium, potassium etc., by carbon is
thermodynamically not feasible.
Such metals are extracted from their ores by using electrochemical methods. In this technique,
the metal salts are taken in a fused form or in solution form.
The metal ion present in can be reduced by treating it with some suitable reducing agent or by
electrolysis.
Gibbs free energy change for the electrolysis process is given by the following expression,
ΔG° = -nFE°
n = number of electrons, F = Faraday, E° = Electrode potential of the redox couple
If E0 is positive then the ΔG is negative and the reduction is spontaneous and hence a redox
reaction is planned in such a way that the e.m.f of the net redox reaction is positive.
ADDITIONAL QUESTIONS:-
1. Explain the Gravity separation method.
High specific gravity ore separated from less specific gangue.
The crushed ore treated with rapidly flowing current of water.
The lighter gangue particles are washed away by running water.
Oxide ores and native ores are concentrated by this method.
Ex. Tin stone, Haematite, Gold ore..
2. Explain the Froth flotation process.
Principle: The metallic ore particles preferentially wetted by oil while impurities preferentially
wetted by water.
Example : Sulphide ores like galena (PbS), zinc blende (ZnS)
Frothing agent : Pine oil
Collector : Sodium ethyl xanthate
Depressing agent : Sodiun cyanide
The crushed ore is mixed with water and pine oil
Froth is produced by blowing air through this mixture.
The collector molecule attached to ore particles and makes them water repellent.
The ore particles rise to the surface along with froth and collected separately.
Impurities settle at the bottom of the container.
When sulphide ore of a metal contains other metal sulphide as a impurities depressing agents are
used to selectively prevent other metal sulphides from coming to the froth.
For Eg. Impurity ZnS present in PbS sodium cyanide (NaCN) is added to depress the
flotation property of ZnS by forming a layer of zinc complex Na 2[Zn(CN)4]
3. Explain the magnetic separation method.
It is based on the difference in the magnetic properties of the ore and the impurities.
This method is applicable for ferromagnetic ores.
Ex. Tin stone ore can be separated from wolframite impurity which is magnetic.
The crushed ore is added onto an electromagnetic separator. It consisting of a moving belt over two
rollers, one is magnet.
The magnetic part of the ore attracted towards the magnet and falls near to the magnetic region.
Non magnetic part of the ore falls away from the magnetic region.
This method is applicable for sulphide ores such as ZnS, PbS etc., it can be done by treating them with
hot aq. H2SO4.
In this process insoluble sulphide is converted into soluble sulphate and sulphur.
Concentrated ore is heated with excess of oxygen in a furnace below the melting point of the metal.
This method is applicable for sulphide ores.
Ex. 2ZnS + 3O2 2ZnO + 2SO2
6. Define calcination.
Simple roasting of some ores give the crude metal even in the absence of a reducing agent.
HgS + O2 Hg + SO2
8. Explain Liquation
This method is used to remove high melting point impurities from low melting point metals.
The impure metal is heated in the absence of air in a sloping furnace.
Pure metal melts and flows down and collected separately.
The impurities remain on the slope.
Eg. Tin, Lead, Mercury, Bismuth..
9. What is cementation?
Gold is reduced to its elemental state when leached solution is treated with Zinc and the process is
called cementation.
Zn(s) +2[Au(CN)2]-(aq) [Zn(CN)4]2-(aq) + 2Au(s)
The remaining metal sulphides Cu2S and FeS are mutually soluble and form a copper matte.
It separated from slag and transferred into converting furnace. During the conversion FeS oxidized to
FeO and removed as slag.
The remaining copper sulphide is further oxidised to its oxide which is subsequently converted to
metallic copper
The metallic copper is solidified and it has blistered appearance due to evolution of SO 2 gas formed
in this process. This copper is called blistered copper.
In this method, a flux and a reducing agent such as carbon, carbon monoxide (or) aluminium is added
to the concentrated ore.
The mixture is melted by heating at an elevated temperature above the melting point of the metal in a
smelting furnace.
Fe2O3(s) + 3CO (g) 2Fe (s) + 3CO2(g)
Carbon dioxide has a linear structure with equal bond distance for the both C-O bonds.
In this molecule there is two C-O sigma bond. In addition there is 3c-4e bond covering all the three atoms
7. Give the uses of silicones.
Used for low temperature lubrication and high temperature oil baths etc...
They are used for making water proofing clothes
They are used as insulating material in electrical motor and other appliances
Mixed with paints to make them resistance towards high temperature, sun light, dampness etc..,
8. Describe the structure of Diborane.
In diborane two BH2 units are linked by two bridged hydrogens. It has eight B-H bonds.
It has only 12 valance electrons and are not sufficient to form normal covalent bond.
The four terminal B-H bonds are normal covalent bonds (2c-2e bond).
The remaining four electrons have to be used by two bridged B – H – B bonds (3c – 2e bond).
In diborane, the boron is sp3 hybridised.
Formation of 2c-2e bond:
Two of the half filled hybridised orbitals of each boron overlap with the 1s orbitals of two
Hydrogens to form four terminal 2c-2e bonds.
Formation of 3c-2e bond:
B–H–B bond formed by overlapping the half filled hybridised orbital of one boron, the empty hybridised
orbital of the other boron and the half filled 1s orbital of hydrogen.
ADDITIONAL QUESTIONS
1. Write the uses of boron.
10
B5 is used as moderator in nuclear reactors.
Amorphous boron is used as a rocket fuel igniter.
Boron is essential for the cell walls of plants.
2. Write the uses of boric acid.
Boric acid is used in the manufacture of pottery glazes, enamels and pigments.
It is used as an antiseptic and as an eye lotion.
It is also used as a food preservative.
3. What is the action of heat on boric acid?
Solid Type
a. P4 Molecular solid
b. Brass Metallic solid
c. Diamond Covalent solid
d. NaCl Ionic solid
e. Iodine Molecular solid
2. Tetragonal a = b c 90
3. Orthorhombic a b c 90
7. Triclinic a b c 90
10. Write short note on metal excess and metal deficiency defect with an example.
Metal Excess defect:-
Metal excess defect arises due to the presence of more number
of metal ions as compared to anions. Ex. NaCl, KCl.
The electrical neutrality of the crystal can be maintained by the
presence of extra cation and electron present in interstitial position.
The anionic vacancies, which are occupied by unpaired electrons, are called F - centers.
=1+3
= 4.
12. Explain AAAA and ABABA and ABCABC type of three dimensional packing with the help of neat
diagram
AAAA type of 3D arrangement:-
It is occurs in simple cubic arrangement.
It can be obtained by repeating AAA type two dimensional arrangements in three dimensions.
Spheres in one layer sitting directly on the top of those in the
previous layers so that all layers are identical.
Each sphere is in contact with 6 neighbouring spheres.
Hence coordination number is 6
3 3
= a
16
3
a3 3
Packing efficiency =
8 100 = 100
a3 8
= 3 x12.5
= 1.732 x 3.14 x 12.5
= 68%
15. What is the 2D coordination number of a molecule in square close packed layer?
The two dimensional coordination number of a molecule in square close packed layer is 4.
In this arrangement each spheres is in contact with four of its neighbours.
16. What is meant by the term “coordination number”? What is the coordination number of atoms in a
bcc structure?
The number of nearest neighbours that surrounding a particular particle in a crystal is called
coordination number.
The coordination number of atoms in bcc structure is 8.
18. Aluminium crystallizes in a cubic close packed structure. Its metallic radius is 125pm. calculate the
edge length of unit cell.
Cubic close packing is based on the fcc unit cell. For fcc
a 2 a
r= (or) r =
4 2 2
a=r2 2
= 125 2 1.414
a = 353.5 pm
19. If NaCl is doped with 10-2 mol percentage of strontium chloride, what is the concentration
of cation vacancy?
For every Sr2+ ion introduced in NaCl crystal, two Na+ ions are removed to maintain electrical
neutrality. One lattice site occupied by Sr 2+ ion and the other remains vacant.
One cation of Sr2+ would create one cation vacancy in NaCl.
Number of cation vacancy created = number of Sr 2+ ions added
Mole percentage of SrCl2 = 10-2
10-2
Mole of SrCl2 = = 10-4 mol
100
No. of ions = n × NA
= 10-4 × 6.023 × 1023
= 6.023 × 1019 Sr2+ ions
Number of cation vacancies = 6.023 × 1019
20. KF crystallizes in fcc structure like sodium chloride. Calculate the distance between K + and F− in
KF. (Given: density of KF is 2 48 g cm−3)
Given,
n = 4 (FCC structure)
ρ= 2.48 gcm-3
M = 58 g mol-1
NA = 6.023 ×1023
a =?
Solution,
nM
=
a3NA
nM 4 58
a3 = =
NA 2.48 6.023 1023
a3 = 0.1553 10-21cm3
a = 0.5375 10-7cm (or) 5.375 10-8cm
1
Distance between K+ and F- = edge length
2
1
= a
2
= 1 5.375 10-8
2
= 2.6875 10-8 cm
= 2.6875 10-10 cm
= 268.75 10-12 cm
= 268.75 pm
21. An atom crystallizes in fcc crystal lattice and has a density of 10 gcm−3 with unit cell edge length
of 100pm. calculate the number of atoms present in 1 g of crystal.
Given,
ρ= 10 gcm3
n = 4 (FCC structure)
a = 100 pm = 100 ×10-12 m = 100 ×10-10 cm = 1.0 ×10-8 cm
W = 1g; M =?
Solution,
nM
=
a3NA
Nf 1
Number of body centre atoms (Y) = = =1
1 1
9. Calculate the packing efficiency of packing in the case of simple cubic crystal.
Let us consider the cube with edge length ‘a’.
Volume of the cube = a × a × a = a3
Radius of the sphere is (r)
a
Here, a = 2r; r =
2
4
Volume of the sphere with radius (r) = r 3
3
3
= =
4 a 4 a3
3 2 3 8
a3
=
6
= 52.3%
Empty space = 47.7 %