CHEM ENG 4058 - Metallurgical Processes

North Terrace Campus - Semester 2 - 2024

This course aims to provide the Chemical Engineering students with an understanding of metallurgy techniques that are used in the processing of minerals. The course provides an introduction to the thermodynamics of pyrometallurgical processes including predominance area and Ellingham diagrams and the physical chemistry and transport phenomena involved in a number of pyrometallurgical unit operations including, agglomeration, roasting, smelting, thermal and electrolytic refining. The course covers the processes used in zinc roasting, copper smelting and refining, iron and steel making, lead smelting and refining, nickel smelting, aluminium production, synthetic rutile and titanium production. At the end of this course you should be able to undertake a range of pyro-metallurgical calculations and have an appreciation of the wide range of thermal processes used to extract useful metals and minerals from their ores. The main topics covered in hydrometallurgy include acid, alkaline and pressure leaching, thermodynamic and kinetic aspects of leaching, purification of leach liquors by ion exchange, solvent extraction, adsorption using activated carbon, selective precipitation operations, and solid-liquid separation techniques. Several practical processes are studied including heap and tank leaching, copper extraction, nickel, zinc, cobalt, gold and uranium processing etc. The main topics in electrometallurgy include Pourbaix diagrams, recovery of metal values by cementation, electrowinning and refining from aqueous solutions, electrolyte preparation, cell potential, effect of additives, aluminium smelting from molten salt electrolytes, design of electrochemical reactors and application of processes for the recovery of copper, zinc, gold and aluminium. At the end of this course you should be able to demonstrate a good understanding of the key factors that govern the successful operation of metallurgical processes in the minerals industry.

Open All

Course Details

Course Code	CHEM ENG 4058
Course	Metallurgical Processes
Coordinating Unit	Chemical Engineering
Term	Semester 2
Level	Undergraduate
Location/s	North Terrace Campus
Units	3
Contact	Up to 4 hours per week
Available for Study Abroad and Exchange	Y
Assessment	Final exam, assignments and case-study

Course Staff

Course Coordinator: Dr Woei Saw

Course Timetable

The full timetable of all activities for this course can be accessed from Course Planner.

Course Learning Outcomes

On successful completion of this course students will be able to:

1	Explain the driving forces behind the thermodynamics and kinetics of leaching and how they impact the design of a hydrometallurgical process;
2	Explain the concepts of solids/liquids separation and how to apply to a process;
3	Discuss the concepts and design of separation and purificaiton including; solvent extraction; ion exchange; precipitation; crystallisation; and membrane treatment;
4	Explain the concepts and design of metal recovery processes including; cementation; reduction; electrowinning and electrolytic refining; and precious metal recovery;
5	Apply basic engineering principles to the design of pyrometallurgical processes; and
6	Explain the thermodynamics, kinetics, and physical chemistry of pyrometallurgy.

The above course learning outcomes are aligned with the Engineers Australia Entry to Practice Competency Standard for the Professional Engineer. The course develops the following EA Elements of Competency to levels of introductory (A), intermediate (B), advanced (C):

1.1	1.2	1.3	1.4	1.5	1.6	2.1	2.2	2.3	2.4	3.1	3.2	3.3	3.4	3.5	3.6
A	—	C	A	C	A	C	C	C	—	A	—	A	C	A	A

University Graduate Attributes

This course will provide students with an opportunity to develop the Graduate Attribute(s) specified below:

University Graduate Attribute	Course Learning Outcome(s)
Attribute 1: Deep discipline knowledge and intellectual breadth Graduates have comprehensive knowledge and understanding of their subject area, the ability to engage with different traditions of thought, and the ability to apply their knowledge in practice including in multi-disciplinary or multi-professional contexts.	1-6
Attribute 2: Creative and critical thinking, and problem solving Graduates are effective problems-solvers, able to apply critical, creative and evidence-based thinking to conceive innovative responses to future challenges.	1-7
Attribute 3: Teamwork and communication skills Graduates convey ideas and information effectively to a range of audiences for a variety of purposes and contribute in a positive and collaborative manner to achieving common goals.	7

University Graduate Attribute

Course Learning Outcome(s)

Attribute 1: Deep discipline knowledge and intellectual breadth

Graduates have comprehensive knowledge and understanding of their subject area, the ability to engage with different traditions of thought, and the ability to apply their knowledge in practice including in multi-disciplinary or multi-professional contexts.

1-6

Attribute 2: Creative and critical thinking, and problem solving

Graduates are effective problems-solvers, able to apply critical, creative and evidence-based thinking to conceive innovative responses to future challenges.

1-7

Attribute 3: Teamwork and communication skills

Graduates convey ideas and information effectively to a range of audiences for a variety of purposes and contribute in a positive and collaborative manner to achieving common goals.

Learning Resources

Required Resources

Hydrometallurgy– Fundamentals and Applications, Michael L. Free, Wiley 2013
ISBN: 978-1-118-23077-0

Recommended Resources

Extractive Metallurgy of Uranium, Robert C. Merritt, 1971
ISBN: 0918062101

Extractive Metallurgy of Copper, Schlesinger, M. E., King, M. J., Sole, K. C., & Davenport, W. G., 5th Ed
ISBN: 978-0-08-096789-9

Online Learning

Students are expected to be able to use various sources of online content to apply to their learning.

Basic cource information will be supplied on MyUni.
Learning & Teaching Activities

Learning & Teaching Modes

The course will be delivered via weekly online mini-lectures and on-line quizzes which are to be completed before weekly workshops.
Workshops will be focussed on explanations of problems and solutions to them.

Weekly tutorials will allow students to investigate problems in more detail.

Workload

The information below is provided as a guide to assist students in engaging appropriately with the course requirements.

The course will consist of weekly 2 hour workshops with required pre-viewing of an on-line mini-lecture and participation in an on-line quiz. Tutorials will be held on a weekly basis of up to 2 hour.

As a guide, 12 hours per 3 unit course is expected weekly. 3 unit courses are required to have a minimum workload of 156 hours regardless of the length of the course.

Learning Activities Summary

Week 1: Introduction, Communition and Flotation
Week 2: Water Chemistry
Week 3: Leaching Principles and Practice
Week 4: Solids/Liquids Separation
Week 5: Solvent Extraction/Ion Exchange
Week 6: Ion Exchange, Precipitation and Crystallisation
Week 7: Electrowinning and Electrorefining
Week 8: Ellingham Diagram
Week 9: Fluidised Bed Roasting
Week 10: Bauxite to Aluminium
Week 11: Iron Making
Week 12: Revision

The University's policy on Assessment for Coursework Programs is based on the following four principles:

Assessment must encourage and reinforce learning.
Assessment must enable robust and fair judgements about student performance.
Assessment practices must be fair and equitable to students and give them the opportunity to demonstrate what they have learned.
Assessment must maintain academic standards.

Assessment Summary

Assessment Task	Weighting (%)	Individual/ Group	Formative/ Summative	Due (week)*	Learning outcomes
Online quizzes	5	Individual	Formative	Most weeks	1. 2. 3. 4. 5. 6. 7.
Assignments	25	Group	Formative	Most weeks	1. 2. 3. 4. 5. 6. 7.
Tests	20	Individual	Summative	Weeks 6, 12	1. 2. 3. 4. 5. 6. 7.
Final exam	50	Individual	Summative	Exam period	1. 2. 3. 4. 5. 6. 7.
Total	100

* The specific due date for each assessment task will be available on MyUni.

This assessment breakdown complies with the University's Assessment for Coursework Programs Policy.

Assessment Detail

Online quizzes are based on the theoretical content.

Assignments: Problem-solving questions based on the theoretical content

Mid Semester Test: Closed-book test in week 6 or 7, covering the first half of the content.

End of Semester Test: Closed-book test in the week 12, covering the first half of the content.

Final Exam: 2 hour, closed-book exam.

Submission

No information currently available.

Course Grading

Grades for your performance in this course will be awarded in accordance with the following scheme:

M10 (Coursework Mark Scheme)
Grade	Mark	Description
FNS		Fail No Submission
F	1-49	Fail
P	50-64	Pass
C	65-74	Credit
D	75-84	Distinction
HD	85-100	High Distinction
CN		Continuing
NFE		No Formal Examination
RP		Result Pending

Further details of the grades/results can be obtained from Examinations.

Grade Descriptors are available which provide a general guide to the standard of work that is expected at each grade level. More information at Assessment for Coursework Programs.

Final results for this course will be made available through Access Adelaide.

Student Feedback

The University places a high priority on approaches to learning and teaching that enhance the student experience. Feedback is sought from students in a variety of ways including on-going engagement with staff, the use of online discussion boards and the use of Student Experience of Learning and Teaching (SELT) surveys as well as GOS surveys and Program reviews.

SELTs are an important source of information to inform individual teaching practice, decisions about teaching duties, and course and program curriculum design. They enable the University to assess how effectively its learning environments and teaching practices facilitate student engagement and learning outcomes. Under the current SELT Policy (http://www.adelaide.edu.au/policies/101/) course SELTs are mandated and must be conducted at the conclusion of each term/semester/trimester for every course offering. Feedback on issues raised through course SELT surveys is made available to enrolled students through various resources (e.g. MyUni). In addition aggregated course SELT data is available.
Student Support
Policies & Guidelines
This section contains links to relevant assessment-related policies and guidelines - all university policies.
Fraud Awareness

Students are reminded that in order to maintain the academic integrity of all programs and courses, the university has a zero-tolerance approach to students offering money or significant value goods or services to any staff member who is involved in their teaching or assessment. Students offering lecturers or tutors or professional staff anything more than a small token of appreciation is totally unacceptable, in any circumstances. Staff members are obliged to report all such incidents to their supervisor/manager, who will refer them for action under the university's student’s disciplinary procedures.

The University of Adelaide is committed to regular reviews of the courses and programs it offers to students. The University of Adelaide therefore reserves the right to discontinue or vary programs and courses without notice. Please read the important information contained in the disclaimer.

Authorised by:	Deputy Vice-Chancellor and Vice-President (Academic)
Maintained by:	Course Outlines Administrator