C - 14 CURRICULUM FOR METALLURGY

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Mineral Processing Technology

Subject Title          :Mineral Processing Technology
Subject code          :      Met – 105
Periods/week         :      04
Periods/Year         :     120

TIME SCHEDULE

S.No         
Major Topics
Periods 
Weightage of Marks    
Short Type  
Essay
Type
1
Ores & ore dressing   
12
09
3
-
2
Ore sampling
14
13
1-
1
3
Comminution 
20
26
2
2
4
Sizing
16
13
1
1
5
Classification 
18
13
1-
1
6
Concentration
20
26
2
2
7
Concentration processes of some important ores.
20
10
0
1

Total
120
110
10
8

OBJECTIVES:

After the completion of course the student should be able to comprehend the following:

1.0       Ores & ore dressing
1.1       Define Native Metal, Mineral, Ore & Ore Dressing.
1.2       Know the minerals of commercially important Metals such as Iron, Al, Cu, Zn., Mg., Ti., U., Th., Pb, Sn,.
1.3       Knowl the metal content & chemical composition of the minerals of the above Metals.
1.4       Know the advantages of mineral / ore dressing.
1.5       State the Important operations of Ore   Processing.

2.0       Ore Sampling
2.1       State the need for study of ore sampling.
2.2       Define sample & sampling.
2.3       State the rules for sampling.
2.4       Classify the sampling operations
2.5       List the types of hand sampling methods.
2.6       Explain Grab, Trench, pipe sampling and coning & Quartering and Fractional selections.
2.7       Explain the principle of mechanical sampling.
2.8       Explain the working principle of Vezin sampler

3.0       Comminution
3.1       Define Comminution& State the objectives of Comminution.
3.2       Classify the Comminution processes.
3.3       State the principles of crushing
3.4       Classify the crushing operations.
3.5       Explain the working principle & operation of Blake & Dodge Jaw Crushers
3.6       Explain the working principle & operation of roll crusher.
3.7       Define ‘Angle of NIP’ of roll crusher.
3.8       Derive an equation for angle of NIP.
3.9       Define grinding & Compare crushing & grinding.
3.10     Classify the Grinding Mills.
3.11     Explain the working principle & operation of Spherical / Conical Ball Mill.
3.12     State the Laws of Comminution  - Rittinger’s ,Kick’s and Bond’s laws.

4.0       Sizing
4.1       Understand the importance of sizing.
4.2       Know the sizing Methods.
4.3       Define screening & Classify
4.4       Define Mesh number & Mesh Size
4.5       Know designating the Mesh numbers as Per ISI.
4.6       Explain the method of making screen analysis  byRotap sieve shaker.
4.7       Tabulate the results of screen analysis by direct plot & cumulative plot methods.
4.8       Know the types of Industrial screens.
4.9       State the equation for capacity of screens.
4.10      Know the factors effecting the capacity of screens.

5.0   Classification
5.1       Know the movement of solids in fluids – Principles of free settling and hindered settling.
5.2       Know about Laminar and turbulent flow of fluids ,Reynolds Number and its expression.
5.3       Know the principle of classificaton
5.4       Know the mechanism of classification in relation to Stoke’s law of settling.
5.5       Explain the working principle of Dorr rake classifier and of hydrocyclone classifier

6.0       Concentration
6.1       Define Concentration & State the objectives of Concentration
6.2       State the principles of Concentration.
6.3       Define concentrate, tailing & middling.
6.4       Classify the concentration operations.
6.5       Explain the working principle of magnetic separator.
6.6       List the gravity concentration processes.
6.7       Explain the sink & float technique.
6.8       Explain the working principle of tabling.
6.9       Explain the principle of jigging.
6.10     Explain the jigging process. (Harz Jig only).
6.11     Define froth flotation.
6.12     Explain the flotation process.
6.13     Define the froather, collector, activator, depressor & conditioner with suitable examples.
6.14    Explain the operation of Denver flotation cell
6.15    Electrostatic separation –principle and operation. 

7.0  Concentration processes of some important ores
7.1     Know and explain the flow sheet of bauxite ore processing.
7.2     Know and explain the flow sheet of coal washing.
7.3     Know and explain the flow sheet of iron ore processing
7.4     Know and explain the flow sheet of gold ore processing.
7.5     Know and explain the flow sheet of lead/zinc concentration.


COURSE CONTENTS:


1.0 ORES AND ORE DRSSING:
Definition of native metal,mineral, ore & ore dressing, minerals of commercially important metals, metal content and chemical composition of the important ores, advantages of ore dressing.,important operations of ore dressing.

2.0 ORE SAMPLING:
Introduction- Rules for sampling –classification-Hand sampling methods-principle of Mechanical sampling.

3.0 COMMINUTION:
Introduction – stages of crushing, primary crushing: Blake type jaw crusher-secondary crushing: Roll crusher- Angle of Nip of Roll crusher –grinding: Definition & classification- Ball mill – comparison of crushing & grinding. Laws of Comminution.

4.0 SIZING:
Introduction – sizing methods- screening types- mesh size & mesh number- ISI
Designation of mesh number-screen analysis by Rotap sieve shake –tabulation of results-
capacity of screen and effecting factors.

5.0 CLASSIFICATION:
Introduction –movement of solids in fluids-free settling,hindered settling ,laminar flow ,turbulrntflow,Reynolds number-derivation,principle of classification,Stoke’s law of settling – mechanism of classification,working principle of mechanical classifier Dorr’s classifier and centrifugal classifier Hydrocyclone classifier.

6.0 CONCENTRATION:
Introduction-principles of concentration-Definitions of concentrate, tailing & middling –concentration Methods-Magnetic separator- gravity concentrations processes-sink & float technique, tabling, Jigging- froth flotation – process & additives.

7.0 CONCENTRATION OF SOME IMPORTANT ORES:
Explanation about the processing of aluminium ore – bauxite - flow sheet, Processing of coal- main operations and flow sheet,Main concentration processes of iron ores - flow sheet,Floatation of gold ores – flow sheet.Concentration flow sheet of lead/zinc.



Books Recommended

1.         Principles of Mineral Dressing                           -        Gaudin
2.         Elements of metallurgy                                      -        Dr.Swaroop
3.         Ore Dressing                                          -                      S.K. Jain
4.          Non-Ferrous extractive Metallurgy                -        Ray. Abraham and Sridhar

 

 

 

 




















Elements of Metallurgical Engineering
Subject Title     :Elements of Metallurgical Engineering
Subject code      :   Met – 106
Periods/week     :   04
Periods/Year     :120

TIME SCHEDULE

S.No   
Major Topics
Periods 
Wheightage of Marks    
Short Type  
Essay
Type
    1                 
Introduction to metallurgy           
15
09
3
0
2
Ferrous, nonferrous  metals and their alloys.
20
23
1
2
3
Principles of extractive  metallurgy-pyro metallurgy
22
23
1
2
4
Principles of extractive  metallurgy–Hydrometallurgy
18
13
1
1
5
Principles of extractive  metallurgy-Electrometallurgy  
20
16
2
1
6
Manufacturing processes
25
26
2
2

Total
120
110
10
08

OBJECTIVES
After the completion of course the student should be able to comprehend the following:

1.0      Introduction to metallurgy.
1.1       Define material and classify them.
1.2       Define metal and state it’s properties.
1.3       Classify the metals.
1.4       Define metallurgy and state its importance.
1.6       Classify the divisions of metallurgy and explain them.
1.9        State the economic importance of metallurgical Industries.
1.10      List out important metal extraction plants in India.
             a) Integrated Iron & steel plants.
                         b) Aluminium plants
                         c) Copper plants
                         d) Zinc & lead plants.

2.0       Ferrous,Non-FerrousMetalsandtheiralloys
2.1       Statethebasisofclassificationofplaincarbonsteels.
2.2       Listouttheapplicationsofthesteels.
2.3       Statetheneedforalloyingthesteelwithotherelements.
2.4       Statethecomposition,properties,and industrialapplicationsof alloysteels.
2.5    Know the properties of tool steels
2.6        Know the composition  and properties of high speed tool steels.
2.7        Know the composition of special cutting materials like satellites,cemented carbides
2.8        Know the classification of cast irons – Gray ,white,malleable,spheroidal- composition,properties and applications.
2.9Know theneedfornon-ferrousmetalsandtheiralloysinengineering application.
3.0List outthecomposition,properties,andindustrialapplicationofthe important–non-ferrousalloys like brass,bronze,muntz metal .
3.1       Knowthepropertiesof bearing metals.


3.0       Principles of extractive metallurgy - Pyrometallurgy
3.1       State the salient features of extractive metallurgy
3.2       Define the pyrometallurgy& List the Pyrometallurgy operations.
3.4       Explain drying.
3.5       Explain calcination.
3.6       Define roasting & classify the roasting operation.
3.7       Explain the oxidizing, blast, and sulphatise, Autogeneous roasting with chemical reactions.
3.8       Explain multiple hearth roaster, Flash roaster & fluidised Bed Roaster.
3.9       Define smelting.
3.10     Define Flux, Slag, Matte.
3.11     Classify smelting operations
a) Reduction Smelting – Carbothermic&Metallothermic
                        b) Matte Smelting.
3.12     State the importance of Coke as a reducing agent in Carbothermic Reduction
3.13     Define refining & State the purpose of refining.
3.14     List important methods of Refining
3.15     Define Drossing& fire refining.
3.16     Explain Zone Refining.

4.0       Principles of extractive metallurgy - Hydrometallurgy
4.1       Define Hydrometallurgy.
4.2       State advantages & Limitations of Hydro Metallurgy
4.3       List important stages in Hydro Metallurgy
4.4       Define leaching & identify the materials for leaching
4.5       State the properties of leachant.
4.6       List important Leaching operations
4.7       Explain pressure, bacterial, ammonical, Acid & heap leaching.
4.8       Define precipitation.
4.9       Understand briefly the typical flow sheet of Hydrometallurgy.

5.0       Principles of extractive metallurgy - Electroometallurgy
5.1       Define electro metallurgy.
5.2        State advantages & Limitations of electro    Metallurgy
5.3       Classify Electro Metallurgical operations
5.4       Define Electrolysis
5.5       State Farday’s laws of Electrolysis.
5.6       State the principle of electrolysis w.r.t. to Anodic &cathodic reactions
5.7       Explain the electrolysis of molten salts.
5.8       Explain the electrolysis of aqueous solutions.
5.9       State Principle of electrolytic refining.
5.10     State applications of Electrolytic Refining
5.11     State the Principle of Electro Plating
5.12     State the commercial applications of electroplating.

6.0     Manufacturing Processes:
6.1  Know about melting process.,
6.2   Know the different furnaces used for melting like cupola,reverberatory,induction,arc.
6.2 Define casting.
6.3State different casting processes like ingot casting,sandcasting,die casting.
6.3 State rolling operation,
6.4  Know about different types of rolling mills,
6.5 Know the tube making process by using rolling operation.
6.6  State the principle of forging,
6.7 Know the types of forging hammers and press,smith forging ,closed die forging.
6.8  Know the extrusion process by direct method,and  by indirect method.
6.9  Know about different drawing processes– Rod drawing,wiredrawing,deep drawing.
6.10 Know about powder metallurgy process – Production of metal powders,powder
mixing,sintering compacting of powders into shapes,
6.11  State the applications of powder metallurgy.
.

COURSE CONTENTS:

1.0  INTRODUCTION TO METALLURGY:
   Materials classification,metal properties &classification,divisions of metallurgy,economic
importance of metallurgical industries,important metal extraction plants in India.

2.0 FERROUS,NON FERROUS METALS AND THEIR ALLOYS:
 Classification of steels and their applications.need for alloying steels, different alloy steels – their properties,apllications.Properties of tool steels,Properties and composition of high speed tool steel,Composition of special cutting steels – satellites and cemented carbides.Different cast irons – gray,whitemalleable,spheroidal – composition,properties and their applications.Impotant non ferrous metals brass, bronze,muntz metals  – their compositions,properties and applications.Properties of bearing metals.


3.0 PYRO METALLURGY:
Introduction- Types of pyro metallurgical operations- Drying, calcination- Roasting
classification of Roasting operations Multiple hearth roaster, Flash Roaster & fluidised bed
Roaster- smelting- Types of smelting-principle of Reduction smelting & Matte smelting
Refining: Definition & purpose -Types of refining: Drossing, fire reefing & Zone refining


4.0 HYDRO METALLURGY:
Introduction – leaching- properties of leachant –suitable Materials for leaching- types of
leaching methods – precipitation-Typical flow sheet of Hydro metallurgy.

5.0ELECTRO METALLUGY:
Introduction- electrolysis :Definition& principle- cathodic& anodic reactions of electrolysis
Faraday’s laws of electrolysis- electrolysis of molten salt &aqueous  solutions- Electrolytic
refining: principle & applications- Electro plating: principle &applicatications.

6.0 MANUFACTURING PROCESSES:
Melting process,differentfurnaceused for melting – cupola,reverberatory,induction,arc.,
Definition of casting,various casting processes – ingot, sand,die .,Rolling operation,different
rollingmills,tube making process by rolling.,Principle of forging,different types of forging
hammers and press ,smith forging and closed die forging.Process of extrusion by direct method
and indirect method.,Different drawing processes – rod drawing,wiredrawing,deep
drawing.,Powder metallurgy processes – production of metal powders,powder mixing ,sintering
and compacting of powders into shapes.,Powder metallurgy applications.


Books Recommended

1.         Principles of Mineral Dressing                           -        Gaudin
2.         Elements of metallurgy                                      -        Dr.Swaroop
3.         Ore Dressing                                          -                      S.K. Jain
4.          Non-Ferrous extractive Metallurgy                -         Ray. Abraham and Sridhar
5.          Engineering Metallurgy PartII-         R.A.Higgins





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