Watch the movies on VBrick. The movies play back to back starting at the top of each hour and last about 40 minutes. Aluminum is first, Iron/Steel is second. If you miss the beginning or if you want to watch them in more than one session, start at the appropriate time (e.g. start at 20 after the hour to watch only the iron/steel movie). I suggest that you read sections 20.2 and 20.7 in your textbook before watching the movies. The worksheet on the following pages will help you focus on the important concepts and provides practice problems. The key is also attached. ferrante:Fe_Al_film_wksht.doc
SC112 - Worksheet
Film – “Iron and Steel”
During the film: (* indicates that the full reaction can be completed after the film.)
1. How was coal converted into coke?
2. Coke and iron ore were sintered into porous lumps. Why is it important that this material be porous?
3. The pipe that is used to blow heated air into the furnace is called a ______.
4. Write out the chemical reaction that describes the burning of coke:
5.* What two chemical substances are used to reduce the Fe2O3 in the blast furnace? ______
6. What is the name of the large container that was used to move the molten iron along railroad tracks? How many tons of molten iron did it hold?
name: ______capacity: ______
7. How does the density of the slag compare to the density of molten iron?
Slag is (circle one) less dense more dense than molten iron.
8. Identify two uses of the processed slag (either pit slag or pellet form).
1. 2.
9. Because “heat costs money” to industry, the furnaces are not allowed to cool between batches. For what maintenance purpose (cited in the film) are they shut down?
10. Iron and steel differ in carbon content. What percentage carbon was cited in the film?
iron: ______% C steel: ______%C 11. A small rod of cast iron, and a small rod of mild steel, were both subjected to a stretching test. The iron suddenly snapped at just under 6 tons of applied force. How did the steel behave, and at what force did it break?
12.* Before the carbon was removed from iron, sulfur impurities had to be removed. What material was blown through a “lance” to do this?
13. Scrap steel was placed into the steel-making vessel. Two reasons were given; identify ONE of them.
14.* What chemical substance was added (through a lance) to remove part of the carbon?
15. Identify two of the three metals (cited in the film) that might be added to the steel to make an alloy.
1. _____ 2. ______
16. After alloying metals were added, argon was bubbled into the molten mixture through a lance. What was the purpose of this? Why use Ar?
purpose: ______why Ar: ______
After-film questions:
A1. Write balanced reactions describing the reduction of Fe2O3 to Fe, using the reducing agents of question 5.
1.
2.
A2. Write out the balanced chemical reaction associated with question 12.
A3. Write out the balanced chemical reaction associated with question 14.
SC112 - Worksheet Name ______Sec. ______
Film – “Aluminum”
During the film: (* indicates that the full reaction can be completed after the film.)
1. How was the impure bauxite (aluminum oxide ore) first treated to remove impurities?
2. The “red mud” contained the impurities removed from bauxite. What was the principal metal impurity?
3. In a lab test, HgO was simply heated, and pure Hg was obtained. What happened when CuO was heated in the same way?
4.* What was added to reduce CuO to Cu (with heating)?
5. Was Al2O3 reduced by the same process as CuO?
6. In the electrolytic cells, what operating currents and voltages were cited in the film?
current: ______A voltage: ______V
7. What material was used for the anodes in the electrolytic cells?
8.* The anodes were destroyed during the electrolysis. What product did they form?
9. In the film, four metals were cited as possible additions to make special aluminum alloys. Identify two of them. 1. ______2. ______
10. The slag on top of the molten aluminum in the holding furnace was a mixture of Al2O3 and what other aluminum compound?
11. What (barnyard) names were given to the cast aluminum ingots?
500 kg ingot: ______50 kg ingot: ______12. Four possible uses of aluminum were cited. Identify three of them. Do NOT include the thermite reaction as an example.
1. ______
2.______
3. ______
13.* In the thermite reaction, what material was mixed with powdered aluminum?
14. What chemical element was used as a fuse to light off the thermite reaction ?
15. In the laboratory demonstration of the thermite reaction, what property was used to indicate that a new, pure metal was formed as product?
16. What real world application was demonstrated for the thermite reaction?
After-film questions:
A1. Write the balanced reaction describing the reduction of CuO to Cu addressed in question 4.
A2. Write out the balanced chemical reaction associated with question 8.
A3. Write out the balanced chemical reaction for the thermite process of question 13.
SC112 - Worksheet Name ______KEY______Sec. ______Film – “Iron and Steel”
During the film: (* indicates that the full reaction can be completed after the film.)
1. How was coal converted into coke?
heat in the absence of air
2. Coke and iron ore were sintered into porous lumps. Why is it important that this material be porous?
so that gases could move through it while in the furnace
3. The pipe that is used to blow heated air into the furnace is called a ______tuyeres______.
4. Write out the chemical reaction that describes the burning of coke:
C + O2 -> CO2
5.* What two chemical substances are used to reduce the Fe2O3 in the blast furnace? __C__ _CO___
6. What is the name of the large container that was used to move the molten iron along railroad tracks? How many tons of molten iron did it hold?
name: _____torpedo______capacity: ___250 ton______
7. How does the density of the slag compare to the density of molten iron?
Slag is (circle one) less dense more dense than molten iron.
8. Identify two uses of the processed slag (either pit slag or pellet form).
1. roadway materials 2. cement manufacturing insulation (pellet form)
9. Because “heat costs money” to industry, the furnaces are not allowed to cool between batches. For what maintenance purpose (cited in the film) are they shut down?
to re-line it with refractory bricks
10. Iron and steel differ in carbon content. What percentage carbon was cited in the film?
iron: ____4____ % C steel: __<_1_____ %C
11. A small rod of cast iron, and a small rod of mild steel, were both subjected to a stretching test. The iron suddenly snapped at just under 6 tons of applied force. How did the steel behave, and at what force did it break?
it stretched, formed a neck, and then snapped at > 8 ton
12.* Before the carbon was removed from iron, sulfur impurities had to be removed. What material was blown through a “lance” to do this? Mg powder
13. Scrap steel was placed into the steel-making vessel. Two reasons were given; identify ONE of them.
cool molten Fe break up jets of hot Fe as it is poured in
14.* What chemical substance was added (through a lance) to remove part of the carbon? O2
15. Identify two of the three metals (cited in the film) that might be added to the steel to make an alloy.
1. _Mg____ 2. __Cr____ Al
16. After alloying metals were added, argon was bubbled into the molten mixture through a lance. What was the purpose of this? Why use Ar?
purpose: ____stir mixture______why Ar:______it will not react______
After-film questions:
A1. Write balanced reactions describing the reduction of Fe2O3 to Fe, using the reducing agents of question 5.
1. 2 Fe2O3 + 3C -> 4Fe + 3CO2
2. Fe2O3 + 3CO -> 2Fe + 3CO2
A2. Write out the balanced chemical reaction associated with question 12.
Mg + S ---> MgS
A3. Write out the balanced chemical reaction associated with question 14.
C + O2 ---> CO2 SC112 - Worksheet Name ______KEY______Sec. ______
Film – “Aluminum”
During the film: (* indicates that the full reaction can be completed after the film.)
1. How was the impure bauxite (aluminum oxide ore) first treated to remove impurities?
treat with hot NaOH solution
2. The “red mud” contained the impurities removed from bauxite. What was the principle metal impurity? Fe
3. In a lab test, HgO was simply heated, and pure Hg was obtained. What happened when CuO was heated in the same way? nothing
4.* What was added to reduce CuO to Cu (with heating)? H2
5. Was Al2O3 reduced by the same process as CuO? NO
6. In the electrolytic cells, what operating currents and voltages were cited in the film?
current: ______145,000______A voltage: _____4______V
7. What material was used for the anodes in the electrolytic cells?
carbon
8.* The anodes were destroyed during the electrolysis. What product did they form?
CO2
9. In the film, four metals were cited as possible additions to make special aluminum alloys. Identify two of them. 1. ___Fe_____ 2. __Si_____ Mg Mn
10. The slag on top of the molten aluminum in the holding furnace was a mixture of Al2O3 and what other aluminum compound? aluminum nitride
11. What (barnyard) names were given to the cast aluminum ingots?
500 kg ingot: ___sow______50 kg ingot: ______pig______12. Four possible uses of aluminum were cited. Identify three of them. Do NOT include the thermite reaction as an example.
1. _____building ind. - handrail, door frames, window sills______
2._____aircraft______
3. ______cooking foil______electric cables
13.* In the thermite reaction, what material was mixed with powdered aluminum?
Fe2O3
14. What chemical element was used as a fuse to light off the thermite reaction ?
Mg 15. In the laboratory demonstration of the thermite reaction, what property was used to indicate that a new, pure metal was formed as product? magnetism: Al and iron oxide reactants were non-magnetic; Fe product is
16. What real world application was demonstrated for the thermite reaction?
welding railroad track at joints
After-film questions:
A1. Write the balanced reaction describing the reduction of CuO to Cu addressed in question 4.
CuO + H2 ---> Cu + H2O
A2. Write out the balanced chemical reaction associated with question 8.
C + O2 ---> CO2
A3. Write out the balanced chemical reaction for the thermite process of question 13.
2 Al + Fe2O3 ---> Al2O3 + 2 Fe