Extracting Metals from Ores: KS3 Chemistry

Most metals occur in the Earth's crust as ores — compounds mixed with rock. Getting the pure metal out requires a chemical reaction to remove the oxygen or sulphur bonded to it. The method used depends entirely on the metal's reactivity: the more reactive the metal, the more energy-intensive the extraction process.

What is a metal ore?

A metal ore is a naturally occurring rock or mineral from which a metal can be extracted profitably. Most metals exist in ores as oxides (combined with oxygen), sulphides (combined with sulphur), or carbonates (combined with carbon and oxygen).

For example:

Iron is extracted mainly from haematite (iron(III) oxide, Fe₂O₃)

Copper from chalcopyrite (copper iron sulphide) and malachite (copper carbonate)

Aluminium from bauxite (mainly aluminium oxide, Al₂O₃)

Zinc from sphalerite (zinc sulphide, ZnS)

A few unreactive metals — gold, silver, and platinum — occur as the native metal (pure, uncombined element) in the Earth's crust, because they are too unreactive to form compounds under normal conditions.

What is the reactivity series?

The reactivity series ranks metals from most to least reactive. It predicts which extraction method is needed:

Reactivity | Metal | Extraction method
Very high | Potassium (K) | Electrolysis
Very high | Sodium (Na) | Electrolysis
High | Calcium (Ca) | Electrolysis
High | Magnesium (Mg) | Electrolysis
High | Aluminium (Al) | Electrolysis
Medium | Carbon (C) — non-metal, reference point | —
Medium | Zinc (Zn) | Reduction by carbon
Medium | Iron (Fe) | Reduction by carbon (blast furnace)
Low | Tin (Sn) | Reduction by carbon
Low | Lead (Pb) | Reduction by carbon
Very low | Copper (Cu) | Reduction by carbon (or displacement; electrolytic refining)
Unreactive | Silver (Ag), Gold (Au), Platinum (Pt) | Found as native metal; physical separation

The key dividing line is carbon. Metals below carbon in the reactivity series can be extracted by reduction with carbon (a cheaper method). Metals above carbon must be extracted by electrolysis (a more expensive, energy-intensive method).

How does reduction by carbon work?

Reduction means removing oxygen from a compound. Carbon (usually as coke — nearly pure carbon) is a good reducing agent because it is more reactive than the metals below it in the reactivity series, so it can "take" the oxygen away from the metal oxide.

Example — iron in the blast furnace:

Iron ore (haematite, Fe₂O₃) is heated with coke (carbon) and limestone in a blast furnace. The key reaction is:

2Fe₂O₃ + 3C → 4Fe + 3CO₂

Carbon removes the oxygen from iron oxide, forming carbon dioxide and leaving molten iron. The molten iron sinks to the bottom of the furnace and is tapped off.

The limestone (calcium carbonate) is added to remove acidic impurities (mainly silicon dioxide, SiO₂) from the ore as molten slag, which is also tapped off separately.

The blast furnace is one of history's most important industrial processes — humans have extracted iron this way for over 3,000 years (the Iron Age).

How does electrolysis work for reactive metals?

Metals above carbon in the reactivity series (such as aluminium, sodium, and magnesium) cannot be extracted by carbon reduction because carbon is not reactive enough to displace them from their compounds.

Electrolysis uses electrical energy to force a non-spontaneous chemical reaction: decomposing an ionic compound by passing a direct electric current through it when it is molten or dissolved in water.

Example — aluminium from bauxite:

Aluminium oxide (Al₂O₃) is dissolved in molten cryolite (to lower the melting point from ~2000 °C to ~950 °C) and a large direct current is passed through. At the negative electrode (cathode), aluminium ions gain electrons and form molten aluminium metal, which sinks to the bottom and is tapped off:

Al³⁺ + 3e⁻ → Al

This process consumes enormous amounts of electrical energy, which is why aluminium is expensive to produce (and why recycling aluminium saves about 95% of the energy compared with extracting new aluminium from ore).

What are the environmental impacts of metal extraction?

Metal extraction has significant environmental consequences:

Impact | Detail
Habitat destruction | Open-cast and underground mining removes large areas of land
Air pollution | Smelting sulphide ores releases sulphur dioxide (SO₂), which causes acid rain
Water pollution | Acid mine drainage can contaminate rivers and groundwater
High energy use | Electrolytic extraction and blast furnaces consume vast amounts of energy (often from fossil fuels)
CO₂ emissions | Reduction with carbon in the blast furnace releases large quantities of carbon dioxide

Recycling metals reduces all of these impacts — it requires far less energy than primary extraction and avoids the need for mining.

Frequently asked questions

Why can carbon be used to extract iron but not aluminium?

Carbon can only extract metals that are less reactive than carbon itself. Iron is below carbon in the reactivity series, so carbon can displace it from its oxide by taking the oxygen away. Aluminium is above carbon — it is more reactive than carbon — so carbon cannot displace it. Aluminium must instead be extracted by electrolysis, which uses electrical energy to force the reduction.

What is an ore?

An ore is a naturally occurring rock or mineral from which a metal can be economically extracted. Most ores are compounds of a metal — typically oxides, sulphides, or carbonates — mixed with rock (gangue). The ore must be processed to separate the useful metal from the unwanted rock and to remove the element combined with the metal.

Why is gold found as the native metal in nature?

Gold is so unreactive (at the very bottom of the reactivity series) that it does not combine with oxygen, sulphur, or other elements under normal geological conditions. Over millions of years it remains as free gold metal in veins in rocks, river sediments, and alluvial deposits. This low reactivity is also why gold does not corrode or tarnish, making it valuable for jewellery and electrical contacts.

Why is aluminium so expensive even though it is the most abundant metal in Earth's crust?

Aluminium is abundant as aluminium oxide in bauxite ore, but because it is very reactive it cannot be extracted cheaply by carbon reduction. It requires electrolysis — passing a large direct current through molten aluminium oxide — which consumes enormous amounts of electrical energy. That energy cost makes primary aluminium production expensive, which is why recycling aluminium from used cans and foil is economically and environmentally important.

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