|
|
| MINE4001 | Metallurgy | 2+0+0 | ECTS:4 | | Year / Semester | Fall Semester | | Level of Course | First Cycle | | Status | Elective | | Department | DEPARTMENT of MINING ENGINEERING | | Prerequisites and co-requisites | None | | Mode of Delivery | Face to face | | Contact Hours | 14 weeks - 2 hours of lectures per week | | Lecturer | Prof. Dr. Hacı DEVECİ | | Co-Lecturer | | | Language of instruction | | | Professional practise ( internship ) | None | | | | The aim of the course: | | The objective of the module is to provide students with i) the knowledge of pyrometallurgical processes used for the extraction of metals or metal compounds ii) the basic knowledge for the chemical and engineering fundamentals of metallurgical processes, and iii) the skills to perform basic engineering calculations related with pyrometallurgical processes. |
| Learning Outcomes | CTPO | TOA | | Upon successful completion of the course, the students will be able to : | | | | LO - 1 : | learn and understand the basic terminology and fundamental concepts of metallurgy and pyrometallurgy | 1,2,7 | | | LO - 2 : | comprehend the role and importance of pyrometallurgy in extractive metallurgy and the technical, economic and environmental characteristics of pyrometallurgical processes for process selection | 1,2,7 | | | LO - 3 : | comprehend and analyse the chemical principles of pyrometallurgical processes | 1,2,7 | | | LO - 4 : | perform the basic engineering calculations related with pyrometallurgical processes | 1,2,7 | | | LO - 5 : | understand the interactions of pyrometallurgy with the other disciplines including mineral processing, chemistry and thermodynamics with the application of the fundamental knowledge previously gained in related modules | 1,2,7 | | | LO - 6 : | have a knowledge of industrial pyrometallurgical unit processes for the extraction of ferrous and nonferrous metals | 1,2,7 | | | LO - 7 : | design and develop conceptual process flowsheets for ferrous and non-ferrous metal ores | 1,2,7 | | | LO - 8 : | develop self-study, writing and presentation skills for life-long learning and effective communication | 1,2,7 | | | CTPO : Contribution to programme outcomes, TOA :Type of assessment (1: written exam, 2: Oral exam, 3: Homework assignment, 4: Laboratory exercise/exam, 5: Seminar / presentation, 6: Term paper), LO : Learning Outcome | | |
| Introduction to metallurgy: Extractive metallurgy vs physical metallurgy. Basic concepts and terminology. Extractive metallurgy: Pyrometallurgy vs hydrometallurgy. Chemical principles of pyrometallurgical processes. Mass Balance and stoichiometry. Thermochemistry. Chemical equilibrium. Ellingham diagrams. Pyrometallurgical processes and applications. Thermal pretreatment methods: Calcining, roasting, agglomeration, sintering and pelletising. Smelting: Blast furnace, flash smelting furnaces and electric-arc smelting furnaces. Unit operations in pyrometallurgy: Smelting, converting and refining. Pyrometallurgy of copper and iron-steel. Charge and basic engineering calculations. Presentations on selected topics such as production of ferrochrome, nickel, aluminium, cement and ceramic, Waelz and ISP processes for zinc and lead production. |
| |
| Course Syllabus | | Week | Subject | Related Notes / Files | | Week 1 | Introduction to the module. Objectives and scopes, resources, references and assessment. | | | Week 2 | Introduction to metallurgy. Extractive metallurgy versus physical metallurgy. Basic concepts and terminology. The role and importance of metallurgy for the production of metals from ores. Pyrometallurgy as a branch of extractive metallurgy. The role and importance of pyrometalurgy. Pros and cons of pyrometallurgy compared with hydrometallurgy. | | | Week 3 | Pyrometallurgical methods and their general characteristics. Introduction to unit processes in pyrometallurgy. Overview of industrial applications of pyrometallurgical processes. | | | Week 4 | Chemical principles of pyrometallurgical processes: Stoichiometry and gas laws. | | | Week 5 | Thermochemistry. Heat of a reaction. Heat capacity. Change in enthalpy of chemical reactions. | | | Week 6 | Entropy and free energy. | | | Week 7 | Chemical equilibrium. Ellingham diagrams. Fuels and calorific value. | | | Week 8 | Mid-term exam | | | Week 9 | Pyrometallurgical unit processes: Drying and calcination. Roasting: Principles, roasters and applications. Roasting of sphalerite concentrates and refractory gold concentrates. | | | Week 10 | Pyrometallurgical unit processes: Agglomeration methods: Pelletising and sintering. | | | Week 11 | Pyrometallurgical unit processes: Smelting and refining. Methods and furnaces. Industrial applications. | | | Week 12 | Pyrometallurgy of copper. Copper ores. Concentration of copper sulphide ores. Matte smelting. Reverberatory and flash smelting furnaces. Production and refining of blister copper. Peirce-Smith converters. Fire and electrolytic refining.
Charge and basic engineering calculations based on mass balance | | | Week 13 | Iron and steel production. Iron ores and pretreatment operations. Blast furnace operation and production of pig iron. Steel production (Bessemer, BOF and electric arc furnace).
Presentations on selected topics (Industrial operations/plants for chrome, aluminium, ceramic and steel production) | | | Week 14 | Charge and basic engineering calculations based on mass balance.
Presentations on selected topics (Industrial operations/plants for cement, gold refining, Waelz process) | | | Week 15 | Presentations on selected topics (Industrial operations/plants for cement, gold refining, Waelz process)
Overview of the topics covered in the module.
Make-up week for the module. | | | Week 16 | End-of-term exam | | | |
| 1 | Deveci H. 2009. Metalurji ders notları. KTU Maden Mühendisliği Bölümü. (Yayınlanmamış) | | | 2 | Cankurt S. 1972. Ekstraktif Metalurji. ITU Maden Fakültesi. Istanbul. | | | |
| 1 | Rosenqvist T. 1974. Principles of Extractive Metallurgy. McGraw-Hill Kogakusha Ltd.. | | | 2 | Hayes P.C. 2003. Process Principles in Minerals and Materials Production. 3rd Edition. Hayes Publishing, Sherwood, Queensland, Australia. | | | 3 | Davenport W.G.L., King M., Schlesinger M., Biswas A.K. 2002. Extractive Metallurgy of Copper. 4th Edition. Pergamon Press, Elsevier Science, Oxford. | | | 4 | Habashi F. 1997. Handbook of Extractive Metallurgy. Vol 1-4, Wiley-VCH, New York, ISBN 3-527-28792-2. | | | 5 | Gilchrist J.D. 1980. Extraction Metallurgy. 2nd Edition. Pergamon Press, Oxford. | | | |
| Method of Assessment | | Type of assessment | Week No | Date | Duration (hours) | Weight (%) | | Mid-term exam | 8 | | 2 saat | 50 | | End-of-term exam | 16 | | 2 saat | 50 | | |
| Student Work Load and its Distribution | | Type of work | Duration (hours pw) | No of weeks / Number of activity | Hours in total per term | | Yüz yüze eğitim | 2 | 14 | 28 | | Sınıf dışı çalışma | 1 | 10 | 10 | | Laboratuar çalışması | 0 | 0 | 0 | | Arasınav için hazırlık | 2 | 4 | 8 | | Arasınav | 2 | 1 | 2 | | Uygulama | 0 | 0 | 0 | | Klinik Uygulama | 0 | 0 | 0 | | Ödev | 1 | 2 | 2 | | Proje | 0 | 0 | 0 | | Kısa sınav | 0 | 0 | 0 | | Dönem sonu sınavı için hazırlık | 2 | 4 | 8 | | Dönem sonu sınavı | 2 | 1 | 2 | | Diğer 1 | 0 | 0 | 0 | | Diğer 2 | 0 | 0 | 0 | | Total work load | | | 60 |
|