Introduction to Metallurgy

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1 Metallurgy

2 Introduction to Metallurgy Metallurgy deals with extraction and purification of metals from their sources. Very few metals like gold, silver etc. occur in native state, while most other metals occur as their compounds.

3 More electropositive metals like the alkali li and alkali li earth metals occur as their halides and nitrates while less basic metals such as copper, zinc etc., are found as their oxides and sulphides.

4 Extraction of the metal from its sources revolves around the following steps: Concentration of the ore Extraction of the crude metal Purification of the crude metal

5 Types of Metallurgy Pyrometallurgy involves extraction of the metal from its sources in the molten state. t Electrometallurgy involves electrolysis l of the molten metal halide. Hydrometallurgy employs a complexing reagent like a cyanide to dissolve out the metal.

6 Minerals and Ores A mineral is mined out from the bowels of earth and contains larger amounts of gangue, while ore is rich in metal content. t Gangue associated with the ore is usually silica.

7 During the extraction of the metal from its ore, gangue is removed as fusible slag by reaction with a flux.

8 A flux combines with the gangue to form a slag and sometimes helps in lowering the melting point of the ore.

9 Purification of the crude metal Liquation is used to purify low melting metals such as lead and tin. Electro refining is used to get pure metals. During this process, crude metal is made the anode and a thin foil of the pure metal is connected to the cathode.

10 The electrodes are dipped in a solution of the metal salt and electrolysed when pure metal is deposited on the cathode. Anodic mud obtained during the process is processed to get other metals present. Zone refining is a specific method to get ultra pure zirconium and silicon.

11 Nernst Distribution law At constant temperature, a solute distributes itself between two immiscible solvents such that the ratio of its concentration in the two solvents is a constant.

12 Parke s process: Molten argentiferous lead is treated with molten zinc when silver present in the lead dissolves in zinc and is removed as silver-zinc alloy. From this, the silver is recovered.

13 Ellingham diagrams These are graphs in which standard free energies of formation of oxides, sulphides etc., of metals are plotted versus increasing temperatures.

14 Equation: G 0 = H 0 - T S 0 As temperature increases, G 0 also increases and hence oxides are unstable at high temperatures.

15 CO is a better reducing agent for Haematite below C and Coke reduces better beyond C. Oxides of Chromium and Manganese are reduced by Aluminium.

16 Metallurgy of Iron Powdered concentrated haematite is calcined. It is mixed with lime stone and coke in the ratio of 8:1:4.

17 The charge is fed into blast furnace where hot air is blown up. Coke burns to give CO 2 and the reaction being exothermic moves CO 2 upwards.

18 CO 2 is reduced to CO by carbon. CO 2 + C 2CO At the top of the furnace, CO reduces Fe 2 O 3 to iron. Fe 2 O3 + 3CO 2Fe + 3 CO 2

19 Industrially Important Compounds Manufactures of Caustic Soda, Ammonia, Sulphuric Acid and Potassium di chromate.

20 d-block Elements The d-block elements are those elements whose atoms or ions in the ground state have partially filled d-sub shell. General configuration [Noble gas] (n-1) d 1-10 ns 1-2.

21 These elements show variable oxidation states, magnetic behavior, form colored compounds and stable co-ordination compounds. They are also good industrial catalysts.

22 Questions

23 1) Which of the following statements is false? a) The ore is free from almost all non-metallic impurities. b) During roasting, moisture is removed from the ore. c) Concentrated zinc blend is subjected to calcination during extraction. d) Calcination is carried out in absence of air.

24 Answer: c) Concentrated t zinc blend is subjected to calcination during extraction.

25 2) In chromite ore, oxidation number of iron and chromium are respectively: a) +3, +6. b) +3, +2 c) +2, +3 d) +2, +6

26 Answer c) +2, +3

27 3) The yellow precipitate formed during the chromyl chloride test is chemically. a) lead chromate b) chromic acid c) sodium chromate d) lead acetate

28 Answer a) lead chromate

29 4) 1 gram of silver gets distributed between 10 cc of molten zinc and 100 cc of molten lead at C. The percentage of silver still left in the lead layer is approximately. a) 5 c) 1 b) 2 d) 3

30 Answer d) 3

31 5) Of the following transition metals, the maximum numbers of oxidation states are exhibited by a) Manganese (Z=25) b) Iron (Z=26) c) Titanium (Z=22) d) Chromium (Z=24)

32 Answer: a) Manganese (Z=25)

33 6) The spin only value of magnetic moment of Mn +4 ion is nearly a) 4 B.M b) 5 B.M c) 3BM B.M d) 6 B.M

34 Answer: a) 4BM B.M

35 7) Carbon can reduce ferric oxide to iron above 983 K because: a) free energy change for the formation of CO 2 is less negative than that t for ferric oxide b) iron has a higher affinity towards oxygen than carbon c) CO formed is thermodynamically less stable than ferric oxide d) carbon has higher affinity towards oxidation than iron

36 Answer: d) carbon has higher affinity towards oxidation than iron

37 8) The ore that t is concentrated t by froth floatation ti is. a) bauxite b) malachite c) zincite d) cinnabar

38 Answer: d) cinnabar

39 9) The order of stability of metal oxides is a) Fe O < Cr O < Al O < MgO b) Fe 2 O 3 < Al 2 O 3 < Cr 2 O 3 < MgO c) Al 2 O 3 < MgO < Fe 2 O 3 < Cr 2 O 3 d) Cr 2 O 3 <M MgO O<AlO 2 O 3 <F Fe 2 O 3

40 Answer: d) Cr O < MgO < Al O < Fe O

41 10) The temperature of the slag zone in the metallurgy of iron using blast furnace is. a) C b) C c) C d) C

42 Answer: b) C

43 11) The function of Fe(OH) 3 in contact process is: a) to remove moisture b) to remove dust particles c) to remove arsenic impurities d) to detect colloidal impurities

44 Answer: c) to remove arsenic impurities

45 12) The incorrect statement t t with respect to Chromyl chloride test is a) formation of Chromyl chloride b) liberation of chlorine c) formation of red vapours d) formation of lead chromate

46 Answer: b) liberation of chlorine

47 13) Which of the following ions has maximum number of unpaired electrons? a) Mg 2+ b) Ti 3+ c) V 3+ d) Fe 2+

48 Answer: c) V 3+

49 14) The highest magnetic moment is shown by the transition metal ion with the configuration: a) 3d 5 b) 3d 2 c) 3d 9 d) 3d 7

50 Answer: a) 3d 5

51 15) Which of the following ions has maximum number of unpaired electrons? a) Mg 2+ b) Ti 3+ c) V 3+ d) Fe 2+

52 Answer: c) V 3+

53 16) When a salt was heated with concentrated ce H 2 SO 4, a reddish brown gas is evolved and a red solution is obtained. The salt may be: a) Chloride c) Iodide b) Bromide d) Nitrate

54 Answer: b) Bromide

55 17) G 0 Vs T plot in Ellingham diagram slopes downward for the reaction: a) 2Ag+½O 2 Ag 2 O b) Mg+½O 2 MgO c) CO+½O CO 2 2 d) C +½O 2 CO

56 Answer: d) C +½O 2 CO

57 18) Which of the following reactions taking place in the blast furnace is endothermic? a) 2C+O 2 2CO b) CaCOCO 3 CaO+COO CO 2 c) Fe O +3CO 2Fe+3CO d) C+O 2 CO 2

58 Answer: a) 2C+O 2 2CO

59 19) Which of the following is not affected by concentrated H 2 SO 4? a) H 2 S b) HI c) HBr d) HCl

60 Answer: d) HCl

61 20) In the manufacture of ammonia by Haber s process, N 2 +3H 2 < 2NH 3 ; H= kj. Which of the following conditions is unfavorable? a) Removing ammonia as it is formed b) Increasing temperature c) Increasing pressure d) Reducing temperature

62 Answer: b) Increasing ) g temperature

63 21. When compared to G0 for the formation of Al 2 O 3, G 0 the formation of Cr 2 O 3 is 2 3 a) Higher b) Lower c) Same d) Cannot be predicted

64 Answer: a) Higher

65 22. Which one of the following pairs of ions have the same of electronic configuration a) Ni2+, Co3 b) Fe2+, Mn2+ c) Fe3+, Mn2+ d) Sc3+, Ti3+

66 Answer: c) Fe3+, Mn2+

67 23. Which of the following does not have valance electron in 3d sub shell a) Fe (III) b) Mn (II) c) Cr (I) d) P(o)

68 Answer: d) P(o)

69 24. [ Ti(H 3+ 2 O 6 )] is purple in colour because is complimentary colour of a) Greenish Yellow b) Red c) Green d) Blue

70 Answer: a) Greenish Yellow

71 25. Of the following outer electronic configuration of the atoms the highest oxidation state is exhibited by which one of them? a) (n-1) d 8 ns 2 b) (n-1) d 5 ns 1 c) (n-1) d 3 ns 2 d) (n-1) d 5 ns 2

72 Answer: d) (n-1) d 5 ns 2

73 26. Which one of the following metal ions is coloured a) Cu + b) Zn 2+ c) Sc 3+ d) V 4+

74 Answer: d) V 4+

75 27. Which one of the following shows highest magnetic moment a) V 3+ b) Cr 3+ c) Fe 3+ d) Co 3+

76 Answer: c) Fe 3+

77 28. The function of iron powder in Haber s method for the manufacture of NH 3 is to 3 a) Increase the yield of NH 3 b) Establish the equilibrium earlier c) Proceed the reaction under low pressure d) act as promoter

78 Answer: b) Establish the equilibrium earlier

79 Q29. A mixture of ammonium nitrate and aluminum powder is used as explosive under the name a) Amatol b) Amonal c) Blasting TNT d) RDX

80 Answer: b)amonal

81 30. The catalyst used in Haber s process is molybdenum. The function of Mo is to a) increase the rate of combination of gases b) remove the impurities present in the gases c) increase the activity of the catalyst d) establish the Equilibrium i

82 Answer: c) increase the activity of the catalyst

83 31. Oleum is a) castor oil b) oil of vitriol c) H 2 SO 4 d) H 2 S 2 O 7

84 Answer: d) H 2 S 2 O 7

85 32. Concentrated Sulphuric acid acts as a) Oxidizing agent b) Dehydrating agent c) Both d) Reducing nature

86 Answer: c) Both

87 33. When hydrogen peroxide is treated with cold acidified K 2 Cr 2 O 7 solution containing ether a blue colour is obtained this is due to a) Chromium m sulphate b) Potassium chromate c) Perchromic acid d) Chromium pentoxide

88 Answer: d) Chromium pentoxide

89 34. NaOH is manufactured by electrolysis of brine, the products of the reaction are a) Cl 2 and H 2 b) Cl 2 and Na c) Cl 2 and sodium amalgam d) Cl 2 and O 2

90 Answer: a) Cl 2 and H 2

91 35. The structure of ammonia molecule is a) Pyramidal b) Triangular c) Square planar d) Linear

92 Answer: a) Pyramidal

93 36. When oxalic acid is dehydrated d d by concentrated t H 2 SO 4 then it forms 2 4 a) C+CO 2 b) CO c) CO 2 d) CO+CO 2

94 Answer: d)co+co2

95 37. Liquid ammonia is used in refrigeration because of its a) High degree of vaporization b) Basicity it c) Square planer d) Linear

96 Answer: a) High degree of vaporization

97 38. Potassium chromate is converted into potassium dichromate by adding a) KOH b) Sulphuric acid c) acetic acid d) ammonium hydroxide

98 Answer: b) Sulphuric acid

99 39. Which one of the following transition metal has lowest density a) Copper b) Nickel c) Scandium d) Zinc

100 Answer: c) Scandium

101 40. Oxidation state of osmium (OS) in OSO 4 is a) +4 b) +6 c) +7 d) +8

102 Answer: d) +8

103 41. The catalytic activity of the transition metals and their compounds is due to a) The chemical reactivity b) presence of unpaired electron c) Their unfilled d-orbitals d) Their ability to adopt multiple oxidation states and availability of adsorption sites stes

104 Answer: d) Their ability to adopt multiple oxidation states and availability of adsorption sites

105 42. Cu + ion exists rarely in aqueous solution due to a) oxidation b) reduction c) Disproportination d) Instability

106 Answer: a) oxidation

107 43. Which orbit is present as e g orbital a) d xy b) d x2 y2 c) d yz d) d xz

108 Answer: b) d x 2 y 2

109 44. Which of the following pairs of elements cannot form an alloy a) Zn, Cu b) Fe, C c) Fe, Hg d) Hg, Na

110 Answer: c) Fe, Hg

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