Extractive Metallurgy Course description

Transcription

1 Extractive Metallurgy Course description Statics 3 Cr. Basic concepts, Forces, moments, and couples, Equilibrium of particles and rigid bodies, First and second moments, Structures (trusses, frames, machines), Distributed-force systems, Friction, Virtual work. Prerequisite: Calculus I, General Physics Crystallography 3 Cr. Bonding, crystal systems, Bravais lattice, elements of crystal symmetry, reciprocal lattice, stereographic projection, elements of X-ray crystallography. Prerequisite: General Chemistry Physical Chemistry of Materials 3 Cr. Behavior of gases: equation of state of ideal and real gases, the heat capacity of an ideal gas, mixtures of ideal gases. The first law of thermodynamics: intensive and extensive properties, internal energy and the first law of thermodynamics, chemical equilibrium, enthalpy of formation and the Hess law, the heat of reactions. The second law of thermodynamics, the statistical interpretation of entropy. Prerequisite: Calculus I, General Chemistry Physical Properties of Materials I 3 Cr. Atomic structure of metals, atomic binding, metal structure, crystal defects, classification of alloys, phase diagrams, the solid solution, eutectic, peritectic, monotectic, eutectoid, iron carbon diagram, TTT diagrams, precipitation hardening, ternary diagrams. Prerequisite: Physical Chemistry of Materials Transport Phenomena 3 Cr. Viscosity, an introduction to non-newtonian fluids, shell balance, mechanical energy equations and Bernoulli's principle, an introduction to turbulent flow, Thermal transport and its different mechanisms, one-dimensional thermal conduction, energy equation in Cartesian coordinate system, Cylindrical coordinate system and polar coordinate system, Momentum, heat and mass transfer theory is taught at both the macroscopic and

2 microscopic levels utilizing integral and differential conservation equations, similarities between the three types of transport, dimensionless analysis and time scales, steady- and unsteady-state creeping and laminar flows, viscous and inviscid flows, transport at interfaces, lubrication theory, boundary layer theory, forced and natural convection, Similarities between the three types of transport and relevant mathematical methodologies, fluid mechanics, and heat and mass transfer, transport in porous media and microfluidics, hemodynamics and cell adhesion. Prerequisite: Differential Equations Engineering Drawing I 2 Cr. Projection concepts, Drawing standards, Volume and surface analysis for drawing the third multi-view projection, Isometric and Demetric (oblique & non-oblique) projections, Types of sectional views, Industrial (Assembly and workshop) drawings, Dimensioning. Strength of Materials 3 Cr. General Concepts, Stress, Strain, Safety concepts, Axial loading, Generalized Hooke's law, Torsion of circular & non-circular members, Pure bending, Bending with axial forces, Shear stress in beams, Transformation of stress and strain and yield criteria, Deflection of beams, Stability of equilibrium, Design of columns, Energy and virtual work methods, Statically indeterminate problems, Plastic limit analysis. Prerequisite: Statics Materials Thermodynamics I 3 Cr. Review of thermodynamics laws and functions, reactions involving pure condensed phases and gaseous phase, phase equilibria in a one-component system, solution thermodynamics, free energy-composition and phase diagrams of binary systems, electrochemical systems. Prerequisite: Physical Chemistry of Materials Physical Properties of Materials II 2 Cr. Kinetics of phase transformation in the solid state, diffusion, nucleation, annealing, recrystallization grain growth, diffusional transformation in steels, martensitic transformation. Prerequisite: Physical Properties of Materials I

3 Mechanical Properties of Materials 3 Cr. Behavior of metals under simple and combined stress systems, elements of the theory of elasticity, plastic deformation, elements of the theory of dislocations, strengthening mechanisms. Prerequisite: Physical Properties of Materials I Solidification of metals 2 Cr. The concepts of liquid and solid, solidification of pure metals, conditions for nucleation, homogeneous and heterogeneous nucleation, rate of nucleus formation, interface structure, morphological instability of a solid-liquid interface, perturbation analysis, solidification of alloys, undercooling, solidification of eutectics, constitutional undercooling, growth in pure metal and alloys, distribution coefficient, macrostructure development, classification of alloys according to their freezing range, centerline feeding resistance, the rate of solidification, heat transfer in solidification, segregation, single crystal growth, zone refining, Rapid solidification processing, general characteristics, production methods, microstructural effects. Prerequisite: Transport Phenomena, Physical Properties of Materials II Corrosion and Oxidation 3 Cr. Definition, classification, anodic and cathodic reactions, various type of corrosion, corrosion, tests, materials selection, cathodic and anodic protection, inhibitors, polarization, electrochemical techniques. Prerequisite: Materials Thermodynamics I Metal Forming 3 Cr. Stress and strain, principal stresses and yielding criteria, metalworking theory, effect of temperature and strain rate on workability, metalworking, processes: cold and hot rolling, drawing, extrusion, forging, sheet metal working. Prerequisite: Mechanical Properties of Materials I Foundry 3 Cr. different methods of casting and the comparison with other methods of production, molds and molding materials, general principles of casting, casting cores and their behavior in casting, molding methods, effective factors in mold design including solidification principles, melt casting properties, viscosity, fluidity and the melting metal flow in the mold, sprue and riser systems designing, The stress-strain equations in casting and the forbidding methods of the hot and cold crack generation, residual stresses in casting pieces, detection of

4 defects and their causes. Prerequisite: Physical Properties of Materials I Department of Mining and Metallurgy Engineering Heat Treatment 2 Cr. Iron-Carbon equilibrium diagram, effects of alloying elements and cooling rate on microstructure, pearlite, bainite and martensite transformations, TTT and CCT diagrams, homogenizing, annealing, normalizing, partial annealing, hardening, and tempering, hardenability, case hardening, industrial problems. Prerequisite: Physical Properties of Materials II Principals of metals Extraction I 2 Cr. Principles reactions of ironmaking, iron ores, charge materials, agglomeration (sintering, pelletizing), coking, manufacture of pig iron in the blast furnace, the direct reduction process, principles reactions of steelmaking, steelmaking processes. Prerequisite: Materials Thermodynamics I Principles of Metals Extraction II 2 Cr. Electro chemistry of aqueous solutions, thermodynamics of aqueous solutions, the chemistry of leaching processes, leaching methods, recovery of metals from leach solutions: cementation, electrowinning, solvent extraction and ion exchange, Principles of pyrometallurgical processes: thermodynamics and kinetics of roasting, calcination, smelting, converting, and refining, production of copper, zinc, lead, and aluminum via pyrometallurgical processes, the principle of pyrometallurgy: production of nonferrous metals by pyrometallurgy. Prerequisite: Principles of Physical Metallurgy Selection of Metallic Materials 2 Cr. quality control, selecting materials to optimize multiple properties, materials failure, long-term materials properties, materials behavior under extreme, conditions, corrosion, discussion of design and materials selection strategy, processing and process selection strategy, process economics, life-cycle thinking and eco-design, special topics, Metallic alloys: Fe, Al, Cu, Ni, Zn, Mg, Ti-based. Steelmaking 3Cr. Principal reactions of steelmaking, gases and non metallic inclusions in steel, deoxidation, charge materials and refractories, oxygen steelmaking processes(ld, LADCA, Kaldo, ).Physical chemistry of direct reduction(thermodynamics and kinetics).reducing gas

5 production(catalytic reforming, Partial Oxidation), Direct reduction processes. Use of DRI in electric arc furnaces. Prerequisite: Iron making Production of Non-Ferrous Metals 3Cr. Pyrometallurgy : production of Copper, roasting of sulphide concentrates, chemistry of roasting, matte smelting, industrial furnaces for matte smelting, converting of coppermatte, continuous methods, anod refining, electric refining of copper, production of zinc, lead, fin, aluminum, and magnesium. Pyrometallurgical processes for production of above metals. Prerequisite: principals of Extractive metallurgy II Refractories 2Cr. Crystal structure of ceramics, silicate structures, ceramic raw materials and phase diagrams, processing-properties and application of ceramics, different kinds of refractories, their shapes and testing methods. Kinetics in material engineering 3Cr. The concept of kinetic, a comparison between kinetics and thermodynamics, chemical kinetic, the rate of reactions, rate laws, the order of reactions, theories of reaction rates(collision and activated complex), the effect of temperature, pressure, concentration and catalyst on the rates of reactions. Transport kinetic: A review on mass transfer in metallurgical reactions(diffusion and convection) Ore dressing 3Cr. theory and practice of unit operations including: size reduction-crushing and grinding, size separation-screening and classification, mineral separation flotation, magnetic and gravity separation. Equipment and circuit design and selection. Mass balancing. Laboratory procedures : grindability, liberation, magnetic and gravity separation, floatation and solid-liquid separation. Metallurgical Process Control 3Cr. The purpose of his course is to introduce the key concepts in automatic control. Material and energy balances are extended to unsteady state(dynamic) systems and Laplace transforms are introduced as a means of conveniently representing process control systems and solving ordinary differential equations. First order, second order and

6 integrating systems including dead time are treated with basic controller algorithms. Commonly used sensing, transmission and final control elements are described and depicted in piping and instrumentation diagrams. Metallurgical Calculations 2Cr. Examples of calculations that metallurgical engineers use will be presented to introduce the general topics of metallurgical engineering. Slurries, mass balances and energy calculations are the primary focus. Analytical Chemistry 2Cr. This course first offers an introduction to sampling, error and statistical analysis as applied to analytical chemistry. Specific analytical techniques or concepts covered are: gravimetric and volumetric analyses, aqueous solution equilibrium principally involving complexation equilibria, spectrophotometric analysis, electrochemical methods, atomic spectroscopy, and chromatographic methods. These topics will be covered from the point of view of theory. The experimental application of this material will be covered in the laboratory experiments (see below)