Extraction

Of Metals
By- Shashwat Pandey
Why Extraction
of Metals
Extracting metals is essential for supporting
industrial processes, technological
advancements, and economic growth.

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Metals are crucial for various industries,
including construction, manufacturing, and
electronics, where they are used to create
infrastructure, technological devices, and
renewable energy solutions. The extraction
and processing of metals stimulate
economic activity by generating jobs and
enabling trade...

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Extraction
Of Metals
Taking Place
in Odisha
Metals Found in Odisha-
• Iron
• Aluminium
• Gold
• Tin
• Manganese
Extraction Of
Metals
Taking Place
in
Maharashtra
Metals Found In Maharashtra-
• Chromium
• Copper
• Iron
• Aluminium
• Manganese
 Index
Serial No. Name Of Metal Extracted Page No.

1 Iron 6-8

2 Aluminium 9-11

3 Gold 12-13

4 Tin 14-15

5 Manganese 16-18

6 Chromium 19-21

7 Copper 22-24
 Extraction Of Iron From Iron Ore
•Ore Preparation: The most common
iron ore is hematite (Fe₂O₃) or
magnetite (Fe₃O₄). The ore is first ubtitle lorem ipsum dolor

mined and then crushed and ground to

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increase the surface area for the
extraction process.

•Concentration: The ground ore is

then concentrated to increase the iron
content. This is usually done through a
process called beneficiation, which
involves separating the iron-rich
particles from the waste material
(gangue). Methods include magnetic
6
separation or froth flotation.
• Reduction in Blast Furnace:
• Charge Preparation: The concentrated ore is
mixed with coke (a form of carbon) and limestone
(calcium carbonate) and fed into a blast furnace.
• Blast Furnace Operation: The blast furnace is a
tall, cylindrical structure where the mixture of ore,
coke, and limestone is heated to very high
temperatures (around 1,500°C or 2,732°F). Air (often

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enriched with oxygen) is blasted into the furnace to
facilitate combustion.
• Chemical Reactions: Coke Combustion: Coke
burns in the presence of oxygen to form carbon
dioxide (CO₂) and carbon monoxide).
• Iron Ore Reduction: Carbon monoxide reacts with
the iron ore (mostly iron oxide) to produce molten
iron and carbon dioxide.
Fe2O 3 +3CO→2Fe+3CO2
Fe3O4+4CO→3Fe+4CO2 7
• Limestone Role: Limestone decomposes to
form lime (CaO) and carbon dioxide. The lime
then reacts with the impurities in the ore to
form slag.
CaCO3→CaO+CO2
CaO+SiO 2 →CaSiO 3 (slag)

• Collection: The molten iron, also known as

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pig iron, collects at the bottom of the furnace.
It is periodically drained from the furnace. The
slag, which floats on top of the molten iron, is
also removed and discarded or used in other
applications.
• Refinement: The pig iron from the blast
furnace is not pure iron; it contains impurities
like carbon and other elements. It’s often
further refined in a basic oxygen furnace or
electric arc furnace to produce steel or other 8

iron products.
Aluminium Extraction
from Bauxite
• Extraction of aluminium from bauxite
• Aluminium is a reactive metal, above carbon in
the reactivity series

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• Its main ore, is bauxite, which contains
aluminium oxide
• Aluminium is higher in the reactivity series than
carbon, so it cannot be extracted by reduction
using carbon
• Instead, aluminium is extracted by electrolysis

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The process of aluminium extraction by
electrolysis
• Bauxite is first purified to produce aluminium oxide, Al2O3
• Aluminium oxide is then dissolved in molten cryolite
• This is because aluminium oxide has a melting point of over 2000 °C which would use a lot of energy and
be very expensive
• The resulting mixture has a lower melting point without interfering with the reaction

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• The mixture is placed in an electrolysis cell, made from steel, lined with graphite
• The graphite lining acts as the negative electrode, with several large graphite blocks as the
positive electrodes
• At the cathode (negative electrode):
• Aluminium ions gain electrons (reduction)
• Molten aluminium forms at the bottom of the cell
• The molten aluminium is siphoned off from time to time and fresh aluminium oxide is added to the cell
• Al3+ + 3e- → Al
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• At the anode (positive electrode):
• Oxide ions lose electrons (oxidation)
• Oxygen is produced at the anode:
• 2O2- → O2 + 4e-
• The overall equation for the reaction is:

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• 2Al2O3 → 4Al + 3O2
• The carbon in the graphite anodes reacts
with the oxygen produced to produce CO2
• C (s) + O2 (g) → CO2 (g)
• As a result the anode wears away and has to
be replaced regularly
• A lot of electricity is required for this
process of extraction, this is a
major expense 11
 Extraction of Gold
• 1. Ore Preparation
• Crushing and Grinding: Gold ore is first crushed and ground to
liberate the gold particles from the surrounding rock. This process
increases the surface area for further processing.
• 2. Gold Extraction Methods

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• A. Gravity Separation
• Gravity Separation: This method relies on the density differences
between gold and other materials. Techniques such as panning, sluicing,
and shaking tables are used to concentrate gold particles from the
ore.
• B. Flotation
• Flotation: For gold ores that contain sulfide minerals, flotation is
used to separate gold-bearing sulfides from other materials. The ore is
mixed with water and chemicals that make the gold-bearing sulfides
hydrophobic (repellent to water). Air bubbles are introduced, and the 12
gold-bearing sulfides attach to the bubbles and rise to the surface,
where they can be skimmed off.
• C. Cyanidation
• Cyanidation: This is the most widely used method for extracting gold, especially for low-grade
ores. The process involves the following steps:
• Leaching: The ground ore is treated with a cyanide solution (usually sodium cyanide, NaCN) in a leaching tank.
Cyanide reacts with the gold to form a soluble gold-cyanide complex.
• Separation: The gold-cyanide solution is separated from the ore through various methods, such as filtration or
thickening.
• Recovery: The gold is then recovered from the solution using one of two main methods:
• Carbon Adsorption: The solution is passed through activated carbon, which adsorbs the gold. The gold is then eluted from
the carbon using a hot, caustic solution.

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• Zinc Precipitation: Zinc dust is added to the solution, causing the gold to precipitate out as a solid. Refining: The
precipitated gold is then smelted to produce pure gold bullion.
• D. Amalgamation-This older method involves mixing the gold ore with mercury to form an
amalgam (a mixture of gold and mercury). The gold is then separated from the mercury by heating,
which vaporizes the mercury and leaves behind the gold. This method is less commonly used today
due to environmental and health concerns associated with mercury.
• 3. Gold Refining
• Smelting: The gold concentrate or precipitate is heated in a furnace to separate impurities. Fluxes
like borax and soda ash are added to help remove non-gold materials.
• Electrolytic Refining: In some cases, gold is further purified using electrolytic methods. Gold is
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dissolved in an electrolyte solution and then plated onto a cathode, producing high-purity gold.
 Extraction Of Tin
• 1. Ore Preparation
• Tin Ore: The primary ore of tin is cassiterite (SnO₂), which contains tin
dioxide. Other tin ores include stannite (Cu₂FeSnS₄) and teallite (PbSn₄).
• Crushing and Grinding: The tin ore is first crushed and ground to liberate
the tin particles from the surrounding rock. This increases the surface area for
the subsequent extraction processes.

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• 2. Concentration
• Gravity Separation: Tin ore is often concentrated using gravity separation
methods due to its high density relative to other minerals in the ore. Methods
include:
• Jigging: The ground ore is subjected to a jigging process where it is shaken,
allowing heavier tin particles to settle while lighter gangue material is removed.
• Shaking Tables: The ore is fed onto a shaking table which separates the tin
particles from the waste material based on their density and size.
• Spiral Concentrators: Spiral concentrators use a spiral flow of water to 14
separate the heavy tin particles from lighter gangue material.
• 3. Smelting
• After concentration, the tin ore is smelted to extract pure tin
metal. The smelting process involves:
• 1. Roasting: The concentrated ore is roasted in the presence of
oxygen to remove sulfur and convert the tin dioxide (SnO₂) to
tin oxide (SnO). This step is sometimes omitted if the ore is
already in a suitable form.

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• 2. Reduction: The roasted ore is then mixed with a reducing
agent, usually carbon (coke), and heated in a furnace. This step
reduces the tin oxide to metallic tin. The chemical reaction for
the reduction of tin dioxide is: SnO2+2C→Sn+2CO\text{SnO}_2 + 2\text{C}
\rightarrow \text{Sn} + 2\text{CO}SnO2+2C→Sn+2CO
• 3. Fluxing and Melting: In the smelting furnace, fluxes like
limestone or silica are added to help remove impurities and
form slag. The tin metal collects at the bottom of the furnace,
while the slag (a mixture of impurities and flux) floats on top
and is removed.
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Extraction of Manganese
• 1. Ore Preparation
• Crushing and Grinding: The manganese ore is first crushed and
ground to liberate the manganese particles from the surrounding rock
and to increase the surface area for subsequent processing.
• 2. Beneficiation

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• Concentration: The ground ore is then subjected to various
concentration processes to increase the manganese content and
remove impurities. Techniques include:
• Gravity Separation: Using differences in density to separate
manganese ore from other materials. Methods include jigging and
shaking tables.
• Magnetic Separation: Manganese ore can be magnetic, and magnetic
separation is used to separate magnetic manganese minerals from non-
magnetic impurities.
• Flotation: In some cases, flotation methods are employed to separate
manganese minerals from gangue based on their surface properties. 16
• 3. Reduction
• After concentration, manganese ore is reduced to produce manganese metal. The reduction
process involves:
• A. Production of Ferromanganese
• Preparation: The concentrated manganese ore is mixed with coke (a form of carbon) and fluxes
(like limestone) and charged into a blast furnace or an electric arc furnace.
• Reduction: The mixture is heated in the furnace at high temperatures (around 1,600°C or
2,912°F) to reduce the manganese oxide (MnO₂) to manganese metal. The chemical reactions involved include:

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3MnO2+4C→3Mn+4CO23\text{MnO}_2 + 4\text{C} \rightarrow 3\text{Mn} + 4\text{CO}_23MnO2+4C→3Mn+4CO2
• Formation of Ferromanganese: Manganese is combined with iron to produce ferromanganese,
a common alloy used in steelmaking. The presence of iron helps to reduce the melting point and
improve the quality of the manganese alloy.
• B. Production of Silicomanganese
• Silicon Addition: In another method, manganese ore is mixed with coke and silica (sand) and
smelted in an electric arc furnace to produce silicomanganese, an alloy containing silicon and
manganese. This is used in steelmaking for deoxidizing and alloying purposes.
• Reduction and Alloy Formation: The reaction for producing silicomanganese involves:
2MnO2+2Si+2C→2Mn+SiO2+2CO2\text{MnO}_2 + 2\text{Si} + 2\text{C} \rightarrow 2\text{Mn} + \text{SiO}_2 + 17
2\text{CO}2MnO2+2Si+2C→2Mn+SiO2+2CO
• 4. Refining
• Purification: The crude manganese products from reduction are often further
refined to remove impurities and improve purity. Refining methods can include:
• Hydrometallurgical Processes: Involving leaching of manganese ores with
acids, followed by precipitation or solvent extraction to obtain high-purity
manganese compounds.
• Electrolytic Processes: Used to produce high-purity manganese metal from
manganese salts in solution.

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 Extraction Of
Chromium
• 1. Mining
• Open-Pit Mining: This method is used when the chromite ore is
located close to the surface. The overburden is removed to expose the

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ore, which is then extracted.
• Underground Mining: For deeper deposits, underground mining is
employed. This involves tunneling into the earth to access the ore body.
• 2. Crushing and Grinding
• Crushing: The mined ore is first crushed to break it into smaller
pieces. This step is essential to increase the surface area for the
subsequent processing.
• Grinding: The crushed ore is then ground into finer particles to
liberate the chromite from other minerals.
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 3. Concentration
• Gravity Separation: Chromite ore is often concentrated using gravity
separation techniques because of its high density relative to other minerals.
Methods such as jigging, shaking tables, or spiral concentrators are used.
• Magnetic Separation: Since chromite is magnetic, magnetic separation can
be employed to separate it from non-magnetic materials
4. Beneficiation
• Flotation: In some cases, flotation is used to further separate chromite from

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other minerals. This involves adding chemicals to a slurry to selectively make
the chromite particles hydrophobic and allow them to float.
• Desliming: This process involves removing fine particles or slime that can
affect the efficiency of concentration processes.
5. Smelting
• Reduction: The concentrated chromite is then subjected to high
temperatures in a furnace. Typically, this involves mixing the ore with carbon
(usually in the form of coke) and heating in an electric arc furnace.
• Production of Ferrochrome: During smelting, chromium is reduced to
produce ferrochrome, which is an alloy of iron and chromium. This alloy is 20

then used in steelmaking and other applications.

 6. Refining and Purification
• Conversion: In some cases, further refining is done to convert ferrochrome into pure chromium
or other chromium compounds, depending on the intended use.
• Purification: Techniques such as chemical leaching or electrolytic processes may be used to
purify the chromium.
7. Waste Management
• Tailings Disposal: The waste material left after ore processing (tailings) must be managed

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carefully to minimize environmental impact. This includes safe disposal and possibly recycling of
materials.
• Environmental Control: Measures are implemented to control dust, manage water used in
processing, and minimize pollution.
8. Transport and Storage
• Transport: The final products, such as ferrochrome or chromite concentrates, are transported to
smelting plants or end-users.
• Storage: Proper storage facilities are required to maintain the quality and prevent contamination
of the final products.
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Copper Extraction
1. Mining
• Open-Pit Mining: This method is used for surface deposits where the ore is
located near the surface. It involves removing the overburden (soil and rock)
to access the copper ore.
• Underground Mining: For deeper deposits, underground mining techniques
are employed. This involves digging tunnels to reach the ore.

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2. Crushing and Grinding
• Crushing: The mined ore is first crushed to break it into smaller pieces. This
increases the surface area for subsequent processing.
• Grinding: The crushed ore is ground into a fine powder in mills. This is
essential to liberate the copper minerals from the gangue (waste material).
3. Concentration
• Flotation: The ground ore is mixed with water and chemicals to create a
slurry. In flotation cells, air bubbles are introduced, and copper minerals
attach to these bubbles and float to the surface, forming a froth. This froth is 22
skimmed off and dried to produce a concentrate with a higher copper
content.
4. Roasting (For Sulfide Ores)
• Roasting: The copper concentrate (mainly copper sulfide) is heated in the
presence of oxygen to convert it into copper oxide and sulfur dioxide. This is done
in a furnace at high temperatures.
5. Smelting
• Smelting: The roasted ore is mixed with flux (like silica) and heated in a furnace.
During smelting, copper sulfide is converted into molten copper and slag (a waste
material). The molten copper is separated from the slag.

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6. Conversion
• Conversion: The molten copper from the smelting process is further processed
in a converter furnace to remove impurities. This involves blowing air or oxygen
through the molten copper to oxidize and remove sulfur and other impurities. The
result is blister copper, which contains about 98-99% copper.
7. Electrolytic Refining
• Electrolytic Refining: The blister copper is purified to produce high-purity
copper. This is done using an electrolytic cell where the blister copper is placed as
an anode and a thin sheet of pure copper as the cathode. When an electric current
passes through the electrolyte solution, copper ions migrate from the anode to 23
the cathode, leaving impurities behind. This results in copper with purity of 99.99%.
 8. Copper Products
• Casting: The refined copper is cast into various forms such as cathodes, billets, or rods.
• Fabrication: The copper is then fabricated into end products like wiring, plumbing, and various
industrial components.
9. Waste Management
• Tailings Disposal: The waste material from the grinding and flotation processes (tailings) needs
to be managed carefully to minimize environmental impact.

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• Slag Management: Slag from the smelting process is often processed to recover valuable
metals or safely disposed of.

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Thank
You
Shashwat Pandey
[Link]@[Link]