Objectives

The aim of this course is to develop an understanding of principles of metallurgical processes, reactor design, metallurgical reactions, and development of metallurgical processes. Many of the unique features of metallurgical systems have been described in sufficient detail and numerous illustrative examples have been included so that it should also be useful for future metallurgical engineers working in the development period of new processes and/or in the continuation of the current processes.

Description

This course is intended to serve as a comprehensive course in process engineering metallurgy for an upper undergraduate in the metallurgical engineering & materials science curriculum. Engineering aspects of mineral processing, including unit operations and flow sheets. Science and technology of metal extraction with applications to specific ferrous and non-ferrous metals. The course includes methods for reactors used in iron and steelmaking, non-ferrous metallurgy, handling and use of metallurgical by-products, project task, and scaling-up of some metallurgical reactors and processes.

Outcomes

The students who successfully pass this course gain knowledge, skill, and competency in the following subjects;

1. Describe and explain processes and reactors for extraction and manufacturing of metals and alloys
2. Knowledge of structure and properties of metallurgical matters
3. Basic transport phenomena approaches in the applications of metallurgical processing
4. Estimation of chemical and electrochemical reaction rates based on kinetic perspective
5. Important considerations in reactor design and scaling-up studies
6. Environmental concerns both in current and future metallurgical processes

Contents

Process Metallurgy – An Argosy Through Time, Introduction to Metallurgical Processing, Classification of Metallurgical Reactors, Structure and properties of molten metal and silicate slags, Importance of Transport Phenomena in Metallurgical Processing, Chemical and Electrochemical Reaction Kinetics, Iron and Steel Technology, Electric Furnace Steelmaking, Non-ferrous process principles and product technologies, Process Concept for Scaling-Up and Plant Studies, Environmental aspects and the future of process Metallurgy, Group projects

References

• Treatise on Process Metallurgy -Process Fundamentals, Vol.1, Editor-in-Chief: Seshadri Seetharaman, Elsevier, 2014.
• Treatise on Process Metallurgy -Industrial Processes, Vol.3, Part A. Editor-in-Chief: Seshadri Seetharaman, Elsevier, 2014.
• Process example #1: Crystallizer “Guidelines for Crystallizer Selection and Operation”, www.cepmagazine.org, Oct. 2004.
• Process example #2: Modelling Drying Processes -A Reaction Engineering Approach, Authors: Chen, Putranto, Cambridge Press, 2013.
• Continuous scrap melting in a short rotary furnace, authors: Zhang, Barr, Meadowcroft, Minerals Engineering, 21, 2008.
• Introduction to Process Technology, C. Thomas, 3rd Ed., Delmar Cengage Learning, 2010.
• 23rd European Symposium on Computer Aided Process Engineering, Vol.32, Editors: Kraslawski and Turunen, Elsevier, 2013.
• Metallurgical Problems, Allison Butts,  McGraw-Hill, 1943
• Handbook of Metallurgical Process Design, G.E. Totten, K. Fonatani, L. Xie, Marcel Dekker Inc., 2004.
• Stoichiometry and Thermodynamics of Metallurgical Processes,  Y. K. RaO, Cambridge University Press, 1985.

Useful Links

COCOsimulator.org

C h e m Cad

MIT Open Courseware

The Metallurgical Society (MET-SOC)

Wikipedia

UC Davis ChemWiki

Moments of Presentations

2015 spring – Blast Furnace + (presentation.pdf)

2015 spring – Basic Oxygen Furnace + (presentation.pdf)

2015 spring – Electric Arc Furnace + (presentation.pdf)

2015 spring – Section Rolling + (presentation.pdf)

2015 spring – Secondary Steelmaking + (presentation.pdf)

2015 spring – Plate Rolling + (presentation.pdf)