13.1 Occurrence, preparation, and properties of transition metals  (Page 5/27)

1. Preliminary treatment. In general, there is an initial treatment of the ores to make them suitable for the extraction of the metals. This usually involves crushing or grinding the ore, concentrating the metal-bearing components, and sometimes treating these substances chemically to convert them into compounds that are easier to reduce to the metal.
2. Smelting. The next step is the extraction of the metal in the molten state, a process called smelting, which includes reduction of the metallic compound to the metal. Impurities may be removed by the addition of a compound that forms a slag—a substance with a low melting point that can be readily separated from the molten metal.
3. Refining. The final step in the recovery of a metal is refining the metal. Low boiling metals such as zinc and mercury can be refined by distillation. When fused on an inclined table, low melting metals like tin flow away from higher-melting impurities. Electrolysis is another common method for refining metals.

Isolation of iron

The early application of iron to the manufacture of tools and weapons was possible because of the wide distribution of iron ores and the ease with which iron compounds in the ores could be reduced by carbon. For a long time, charcoal was the form of carbon used in the reduction process. The production and use of iron became much more widespread about 1620, when coke was introduced as the reducing agent. Coke is a form of carbon formed by heating coal in the absence of air to remove impurities.

The first step in the metallurgy of iron is usually roasting the ore (heating the ore in air) to remove water, decomposing carbonates into oxides, and converting sulfides into oxides. The oxides are then reduced in a blast furnace that is 80–100 feet high and about 25 feet in diameter ( [link] ) in which the roasted ore, coke, and limestone (impure CaCO ₃ ) are introduced continuously into the top. Molten iron and slag are withdrawn at the bottom. The entire stock in a furnace may weigh several hundred tons.

Near the bottom of a furnace are nozzles through which preheated air is blown into the furnace. As soon as the air enters, the coke in the region of the nozzles is oxidized to carbon dioxide with the liberation of a great deal of heat. The hot carbon dioxide passes upward through the overlying layer of white-hot coke, where it is reduced to carbon monoxide:

The carbon monoxide serves as the reducing agent in the upper regions of the furnace. The individual reactions are indicated in [link] .

The iron oxides are reduced in the upper region of the furnace. In the middle region, limestone (calcium carbonate) decomposes, and the resulting calcium oxide combines with silica and silicates in the ore to form slag. The slag is mostly calcium silicate and contains most of the commercially unimportant components of the ore: