3f03-exam review exam review april 2015. kc availability: exam review tues april 7 th 11:00-1:00 wed...
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3F03-Exam Review
Exam Review
April 2015
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KC Availability: Exam review
• Tues April 7th11:00-1:00
• Wed April 8th 9:30-12:30
• Thurs April 9th 11:00-1:00
• Tues April 14 12:30-2:30
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Exam Structure
• Four from eight questions.– One from Section 1 ( Process Design;heat &
mass balances)
• 3 hours
• No Books!
• Approved Calculator
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Section
1;
Process
Design
Choice of at least one from two Questions
Will test ability to evaluate an select process options based on calculations of process performance; heat balance, mass balance equilibrium condition
Question 1/ Ironmaking and Iron Ore reduction Process
Question 2/ Design of Copper Making Process
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Section
2;
Specific
Processes
Choose 3 from 6 questions testing knowledge of processes used to extract different metals and use theoretical background to analyse and evaluate these processes.
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Content
• Everything up to and including Tues March 31
• Answers: – About 30-50% calculation– Will test application of concepts to designing
selecting processes.– Knowledge of Processes and understanding
basis of processes
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Learning Objectives
• Thermochemical Fundamentals– Thermodynamics----Can we?---- How can
we?– Heat and mass balance---- how much
energy/product/raw material?
• Be aware of main processes used for materials production
• Be able to relate the design of these processes to the fundamentals.
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What do we consider in design of process?
• Source of raw material
• Form/Chemistry of raw material– Accessibility of valuable content– Concentration of valuable content– Impurities– Chemical form of valuable content
(Oxide/Sulphide)
• Consistent supply
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What do we consider in design of process?
• Heat requirement?
• Appropriate Fuels– Is the fuel also a reactant?– Does the ore provide its own fuel(Autogenous
processing of Sulphides)
• Economic productivity
• Value of product
• Required purity of product
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Materials Processes
• Sulphide Smelting
• Reduction of Oxides in blast Furnace
• Molten Salt Electrolysis for Magnesium and Aluminum Production
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Mass Balance
• Input =Output +Accumulation–Auditing of elements–Principle independent of chemical
changes–Ignores the interchange of energy–Applies to all processes regardless
of complexity
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Heat Balance
• Similar to mass balance– Heat in=Heat out
+Accumulation
Stoichiometric coefficient –ve for reactants +ve for products.
i n
i HH 0
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Heat Balance
• Phase transformation at T2
• Solid State, Melting, Vaporization, Sublimation
3
2
2
2
1
T
T
T
T
T
CpdTHCpdT
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Heat of Reaction
reactf
prodfrxn HHH 298
dTCHHT
pT 298
0298
0
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Heat Balance
• Critical Skills/Issues– Conduct Heat Balance With Multiple Inputs
and Outputs and Incomplete Chemical Reactions
– Calculate the heat of reaction at a new temperature
– Relate the outcomes of heat balance to why we do what we do in a process
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Carbon Fuels
• Learning Objectives– Be able to discuss major characteristics of
metallurgical fuel– Be able to describe the coking process and
coal gasification.– Understand the properties we require from
coke and its role in the blast furnace
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MS
MO2MSO
2 = 0.5S2 +O
2
Me
MeS
MeO
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Process Red Metals M and Me
A/ can directly smelt both
B/ Can directly smelt M not Me
C/ Can directly smelt Me not M
D/ cant directly smelt either me or M
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Process Blue Metals M and Me
A/ can directly smelt both
B/ Can directly smelt M not Me
C/ Can directly smelt Me not M
D/ cant directly smelt either me or M
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0
0 log pO2
log
pS
2MS
MO2
M
SO2 = 0.5S
2 +O2
Me
MeS
MeO
A
B
C
2%M
O2
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Sulphide Smelting
• Utopia– Continuous– Direct– Autogenous (utilize heat available from
sulphur combustion)– Zero Losses
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Sulphide Smelting
• Reality– Most cannot be directly smelted– Those that can have major impurities that
prohibit the direct route– Different approaches– Ways of making continuous direct smelting
work
• Must be able to think of processing of all ores in terms of foregoing?
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Sulphide Smelting Choice
• Lead sulphide can under certain circumstances be directly smelted.
You are asked to consider 2 concentrates:
A/ 50%PbS 50%FeS
B/ 90% PbS 10%FeS
Which will be the most appropriate for direct smelting
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Sulphide Smelting Choice
You are have been asked to increase the purity of your lead Bullion, this will
A/increase lead losses
B/decrease lead losses
Which will be the most appropriate for direct smelting
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Blast Furnaces
• Where the heat comes from– Importance of CO2 in off-gas
– Required properties of coke– Conditions required to make process work
• Desired and undesirable reactions
• Calculate required conditions
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Copper
• Can Directly Smelt
• Major Impurity (FeS) Gets In the Way– Know the process routes and why?– Know the different types of furnace and their
characteristics/advantages
• Always a balance between purity, productivity and loss!
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Flash Smelting of Copper
• Two concentrates
A/ 50%Cu2S 50% FeS
B/ 90%Cu2S 10% FeS
Which will be most amenable to Inco Flash Smelting?
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Nickel
• Not Quite like Copper– Know the similarities and differences– Know the processing options– Know the equipment used– Know and understand the thermochemistry
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Lead
• Also not quite like copper– Could directly smelt but there are challenges– Iron also plays a role
• Prefer blast furnace (not really)– Know the important reactions and where they
occur (desirable and undesirable)
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Zinc
• Can’t Directly Smelt!• Big issue Gas Product!
– Understand complications– Understand thermodynamic solution– Understand kinetic solution
• Blast Furnace– How we avoid reoxidation– Important reactions– Lead splash condenser
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Electrometallurgy
• Main Characteristics of System– How they affect process route (raw materials
treatment)– How they affect cell design
• e.g. density of electrolyte
• Energy optimization– Anode/cathode gap– Electrolyte properties– Production rate
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Iron and Steelmaking
• Ironmaking Including the importance of Coke
• Steelmaking and process steps needed to remove specific impurities.
• Optimum process route for a specific steel