Principles of Primary Metal Production

Course Code:

MSN 301

Course Period:

Autumn

Course Type:

Core

Credits:

3

Theoric:

3

Practice:

0

Laboratory Hour:

0

ECTS:

6

Course Language:

English

Course Coordinator:

Ahmet Turan

Courses given by:

Ahmet Turan

Hatice Kübra Akben

Course Objectives:

The course aims to introduce the basic concepts and processes of up-stream metal production processes. By the end of this course, students should gain information on raw material resources and their pretreatments, the unit operations to convert resources into semi and end products, examples of industrial applications and the principles of metallurgical processes with their thermodynamical features.

Course Content:

Raw materials and their classification; Pretreatment / mineral processing; Dissociation reactions; Roasting; Reduction; Refining and smelting; Leaching and cementation; Electrochemistry of metals; Application of metal production processes in nanotechnology

Course Methodology:

1: Lecture, 2: Question-Answer, 3: Discussion, 9: Simulation, 12: Case Study

Course Evaluation Methods:

A: Written exam, B: Multiple-choice exam C: Take-home quiz, D: Experiment report, E: Homework, F: Project, G: Presentation by student, H: …

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Course Learning Outcomes

Learning Outcomes	Programme Learning Outcomes	Teaching Methods	Assessment Methods
1) Learns the fundamentals of raw materials and raw material preparation for metal production, pretreatments, pyro, hydro and electrometallurgical processes.	1b, 2a	1,2,3	A
2) Knows and applies technologies related to minerals and metallurgical processes depending on their advantages and limitations.	1b, 2a	1,2,3	A
3) Accounts for material and energy balance related to metallurgical processes.	1b, 2a	1,2,3	A
4) Makes economic assessments of metals, metal production and recycling	1b, 2a	1,2,3	A
5) Gains the ability to apply basic knowledge in metal production.	1b, 2a	1,2,3	A

Course Flow

COURSE CONTENT
Week	Topics	Study Materials
1	Introduction to the production processes of metals, alloys and their inorganic compounds	Textbooks and lecture notes
2	Phase separation and mineral processing: Classification; Concentration; Separation of solids from liquids; Gas cleaning	Textbooks and lecture notes
3	Dissociation Reactions: Calcination; Dehydration.	Textbooks and lecture notes
4	Roasting: Total oxidizing roasting; Sulphating; Partial reductive roasting; Halide roasting	Textbooks and lecture notes
5	Reduction: Reductive smelting; Direct reduction; Reduction into gas phase; Reduction from gas phase	Textbooks and lecture notes
6	Smelting and refining: Smelting of metals; Metal-metal separation; Zone refining; Vacuum refining	Textbooks and lecture notes
7	Midterm (1)	Textbooks and lecture notes
8	Kinetics of leaching and precipitation	Textbooks and lecture notes
9	Pressure leaching, reduction and applications	Textbooks and lecture notes
10	Solvent extraction and ion exchange	Textbooks and lecture notes
11	Midterm (2)	Textbooks and lecture notes
12	Electrochemistry of metals – 1: Conductance and transference; Cell types and potentials; Electrochemistry of aqueous solutions.	Textbooks and lecture notes
13	Electrochemistry of metals – 2: Irreversible phenomena; Current and energy efficiency; Applications	Textbooks and lecture notes
14	Applications of the chemical processes of metals and inorganic compounds in nanotechnology	Textbooks and lecture notes
15	Final exam	Textbooks and lecture notes

Recommended Sources

RECOMMENDED SOURCES
Textbook	D.A.Brandt, J.C.Warner, 2005, Metallurgy Fundamentals, Goodheart-Willcox. Seshadri Seetharaman, Fundamentals of Metallurgy, 2005, CRC Press. Fathi Habashi, Hanbook of Extractive Metallurgy, Vol: I-IV, 1997, Wiley.
Additional Resources	Lecture notes

Material Sharing

MATERIAL SHARING
Documents	Shareable
Assignments	Shareable
Exams	Not shareable

Assessment

ASSESSMENT
IN-TERM STUDIES	NUMBER	PERCENTAGE
Mid-Term	2	60
Final Exam	1	40
Total		100
CONTRIBUTION OF FINAL EXAMINATION TO OVERALL GRADE		40
CONTRIBUTION OF IN-TERM STUDIES TO OVERALL GRADE		60
Total		100

Course’s Contribution to Program

COURSE'S CONTRIBUTION TO PROGRAMME
No	Program Learning Outcomes	Contribution
No	Program Learning Outcomes	1	2	3	4	5
1a	Adequate knowledge in mathematics, science and engineering subjects pertaining to the relevant discipline,
1b	Ability to use theoretical and applied knowledge in these areas in complex engineering problems.					X
2a	Ability to identify, formulate, and solve complex engineering problems,					X
2b	Ability to select and apply proper analysis and modeling methods for this purpose.
3a	Ability to design a complex system, process, device or product under realistic constraints and conditions, in such a way as to meet the desired result,
3b	Ability to apply modern design methods for this purpose.
4a	Ability to devise, select and use modern techniques and tools needed for analyzing and solving complex problems encountered in engineering practice.
4b	Ability to employ information technologies effectively.
5a	Ability to design experiments for investigating complex engineering problems or discipline specific research questions,
5b	Ability to conduct experiments, gather data, analyze and interpret results for investigating complex engineering problems or discipline specific research questions.
6a	Ability to work efficiently in intra-disciplinary teams,
6b	Ability to work efficiently in multi-disciplinary teams,
6c	Ability to work individually.
7a	Ability to communicate effectively in Turkish, both orally and in writing,
7b	Knowledge of a minimum of one foreign language,
7c	Ability to write effective reports and comprehend written reports, prepare design and production reports,
7d	Ability to make effective presentations,
7e	Ability to give and receive clear and intelligible instructions.
8a	Recognition of the need for lifelong learning, ability to access information, ability to follow developments in science and technology,
8b	Ability to continue to educate him/herself.
9a	Consciousness to behave according to ethical principles and professional and ethical responsibility.
9b	Knowledge on standards used in engineering practice.
10a	Knowledge about business life practices such as project management, risk management, change management.
10b	Awareness in entrepreneurship and innovation.
10c	Knowledge about sustainable development.
11a	Knowledge about the global and social effects of engineering practices on health, environment, and safety,
11b	Knowledge about contemporary issues of the century reflected into the field of engineering.
11c	Awareness of the legal consequences of engineering solutions.

ECTS

ECTS ALLOCATED BASED ON STUDENT WORKLOAD BY THE COURSE DESCRIPTION
Activities	Quantity	Duration (Hour)	Total Workload (Hour)
Course Duration (Excluding exam weeks: 12xTotal course hours/week)	12	3	36
Hours for off-the-classroom study (Pre-study, practice, review/week)	12	4	48
Studying for midterm exam	2	20	40
Midterm exam	2	2	4
Studying for final exam	1	20	20
Final exam	1	2	2
Total Work Load			150
Total Work Load / 25 (h)			6
ECTS Credit of the Course			6

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Principles of Primary Metal Production

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