Materials 3F03

High Temperature Materials Production
Course Information 2013-2014

INSTRUCTOR: Dr. K. S. Coley	Room: JHE A214	Telephone Ext: 24503	Email: coleyk@mcmaster.ca
TA: Shooka Mahboubi	Room: JHEA206	Telephone Ext: 27226	Email: mahbos@mcmaster.ca

CALENDAR DESCRIPTION
Fundamentals of processing, building on a knowledge of heat and mass transfer. High temperature processing of materials, focusing on heat sources, solid state processing of powders and liquid state processing. Three lectures and one tutorial one term
Prerequisite: MATLS 3A03 or CHEM ENG 2A04, and MATLS 3B03, 3E04

This course parallels MATLS 3B03, and utilizes some of the concepts introduced in the heat and mass transfer courses. It is taught from a generic viewpoint. MATLS 4C03 provides a more specific analysis of modern iron and steelmaking and Matls 4I03 focuses on sustainable materials processing.
This course provides the foundation for Materials Engineers to work as Professional Engineers in the high temperature process industries. The course will emphasize production of metals and also discuss glasses and ceramics. The course will use examples of specific processes to develop an understanding of process fundamentals. Students will learn how to apply these fundamentals to process analysis, design, selection and operation.

In covering these topics students will develop certain aspects of the following CEAB Graduate attributes:

Knowledge Base for Engineering
Problem Analysis
Investigation
Design
Impact on Society and the Environment.

In addition to these attributes which will be taught applied and assessed, aspects of the following attributes will be applied and assessed but not taught:

      Communication
      Teamwork
      Ability to use Modern Engineering Tools

COURSE LEARNING OBJECTIVES:

By the end of the course students will be able to do the following (numbers in brackets refer to the Graduate Attribute Indicators)

1. Analyse heat and mass requirements during high temperature materials processing. (problem analysis 2.1 to 2.3)

2. Apply results of heat and mass balances to process design and selection taking account of constraints imposed by chemical equilibria and environmental impact. (two case studies on process design)(Investigation 3.1 and 3.2, Design 4.1-4.3, Impact on Society and the Environment 9.1)

3. Quantitatively describe the operation of the major pyrometallurgical, ceramic and glassmaking processes. (Knowledge 1.3 and 1.4)

COURSE: MATLS 3F03
EVALUATION (Method & Grade Distribution): 2 Major Tutorial Assignments 15% Weekly Tutorial Question 10% Mid-Term Quiz 25% Final Examination 50%
SPECIAL DATES/DEADLINES: Mid-term quiz TBA
ASSIGNMENT MODE: There will be 2 major assignments (1 worth 10% and 1 worth 5%). In addition to the 2 major assignments there will be short tutorial questions most weeks.
LABORATORY CONTENT (List experiments; no of laboratory sessions/student) N/A
SUPPLEMENTARY TEXTS: A.K. Biswas and W.G. Davenport: Extractive Metallurgy of Copper, 3rd ed., Elsevier, 1994. J.G. Peacey and W.G. Davenport: The Iron Blast Furnace, Pergamon, 1979. T. Rosenqvist: Principles of Extractive Metallurgy, 2nd ed., McGraw-Hill, 1983. B. Deo and R. Boom: Fundamentals of Steelmaking Metallurgy, Prentice Hall, 1993.
OTHER AVAILABLE RESOURCES (software packages, etc.): Custom Courseware available in Bookstore.

POLICY REMINDERS
The Faculty of Engineering is concerned with ensuring an environment that is free of all adverse discrimination. If there is a problem,that cannot be resolved by discussion among the persons involved, individual are reminded that they should contact the Department Chair, the Sexual Harassment Office or the Human Rights Consultant, as soon as possible.
The Senate Resolution on Course Outlines states that:
"students should be reminded that they should read and comply with the "Statement on Academic Ethics and the Senate Resolution on Academic Dishonesty" as found in the Senate Policy Statements distributed at registration and available in the Senate Office.
Academic dishonesty consists of misrepresentation by deception or by other fraudulent means and can result in serious consequences, e.g. the grade of zero on an assignment, loss of credit with a notation on the transcript (notation reads: "Grade of F assigned for academic dishonesty"), and/or suspension or expulsion from the university.
It is your responsibility to understand what constitutes academic dishonesty. For information on the various kinds of academic dishonesty please refer to the Academic Integrity Policy, specifically Appendix 3, located at http://www.mcmaster.ca/senate/academic/ac_integrity.htm
The following illustrates only three forms of academic dishonesty:

Plagiarism, e.g. the submission of work that is not one's own or for which other credit has been obtained. (Insert specific course information, e.g. style guide)
Improper collaboration in group work. (Insert specific course information)
Copying or using unauthorized aids in tests and examinations.

3F03 Course Notes

Week	Date	Topic		Tutorial	Other Notes
1	January 5th	Module 1- Introduction, Mass Balances, Heat Balances		No Tutorial
2	January 12th	Module 1- Supply of Heat, Methods of Heat Generation, process heat and mass balances	T1
3	January 19th	Module 1(cont): Fuels, Drying, Calcining,		T2
4	January 26th	Module 2: Matte Smelting and converting theories. Issues affecting process design.		T3
5	February 2nd	Module 3: Copper theoretical basis of process; effect of impurities on choice/design of process; analysis of energy yield and productivity in different processes; Flash Smelting and Electric Smelting; Matte Converting; Continuous Processes) l		A1 introduced
6	February 9th	Module 3(cont) Module 4: Nickel, Lead and Zinc smelting (examination of how underlying chemistry and ore type, change the way in which processing must be approached, discussion builds on that developed for copper)		Discussion of A1 T4	Assignment #1 – Part 1 Due
7	February 16th	Mid-Term Recess
8	February 23rd	Module 4: Cont		Mid-Term Review	Mid-Term – Date TBD
9	March 6th	Module 5: Electrolytic Processes incl. Al and Mg		Discussion A1 T5
10	March 13th	Module 6: Iron and Steelmaking,		Discussion A1
11	March 20th	Module 7: Sintering		A2	Assignment # 1 – Part 2 Due
12	March 27th	Module 7(cont)			Assignment # 2 Due
13	April 3rd	Misc. Topics and Exam Review		Exam Review

Course Audit Checklist

Type of Activity	Brief Description	Significance (select one)
Tutorials (no new material)	Tutorials on industrial heat and mass balances	üMajor Minor N.A.
Modelling Use of simple mathematical models or software packages.		Major Minor üN.A.
Use of Computerized Databases		Major Minor üN.A.
Design & Synthesis Components	Basis for the Design of Industrial Processes	üMajor Minor N.A.
Integration of Concepts with other courses	Follows 3B03, precedes 4C03 and 4I03	üMajor Minor N.A.
Integrated Laboratory experience		Major Minor üN.A.
Project, with essay, critical assessments		Major üMinor N.A.
Illustration of Industrial relevance (Visual Aids, movies, CD-ROM)	Videos and slides as appropriate	Major üMinor N.A.
Team Projects (other than labs)	Team project on design of process route as a function of ore quality	Major üMinor N.A.
Methods/Components of Assessment	Assignments(1 Team project One individual) Tutorial Questions Mid Term Final Exam	Major Minor N.A.
TA Utilization/ Needs	TA assisting in tutorials and marking assignments.	üMajor Minor N.A.