1. Mining

Metals are extracted from the earth in the form of ores, which are naturally occurring rocks containing metal compounds. Mining methods vary based on the metal and location:

• Open-pit mining – Used for large deposits near the surface.
• Underground mining – Used for deep-lying ores.
• Placer mining – Used for metals like gold found in riverbeds.

2. Ore Processing (Beneficiation)

Once extracted, the ore is crushed and processed to separate the valuable metal from waste material (gangue). Common methods include:

• Crushing & Grinding – The ore is broken into smaller pieces.
• Concentration – Methods like flotation, magnetic separation, or gravity separation remove impurities and increase metal content.

3. Extraction of Metals

The concentrated ore undergoes metallurgical processes to extract the metal:

• Pyrometallurgy (Heat-Based Extraction) – Involves roasting or smelting ores at high temperatures to extract metals like iron, copper, and lead.
• Hydrometallurgy (Chemical-Based Extraction) – Uses chemical solutions to dissolve metals from ores, commonly used for gold, silver, and copper.
• Electrometallurgy (Electric Current-Based Extraction) – Uses electrolysis to extract metals like aluminium from their ores.

4. Refining & Purification

The extracted metal is often impure and requires further purification:

• Electrolysis – Used to refine metals like copper and aluminum.
• Zone refining – Used for high-purity metals like silicon and germanium.
• Chemical refining – Used for precious metals like gold and platinum.

5. Casting & Manufacturing

Once purified, the metal is cast into ingots, sheets, or other forms for use in industries like construction, electronics, and manufacturing.