Course Structure B. Tech. - and Metallurgical Engineering

Applicable to those admitted through JEE from 2019 onwards

Department of Fuel, Minerals and Metallurgical Engineering Indian Institute of Technology (ISM) Dhanbad Dhanbad, Jharkhand, India (September - 2019)

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Course Structure

SEMESTER III S. Subject Subject Name Lecture Tutorial Practical Credit Contact No. ID (L) (T) (P) Hours Hours 1 FMC201 Colloids and interfacial 3 0 0 9 3 phenomena 2 FMC202 Heat and mass transfer 3 0 0 9 3 3 FMC203 Physical separation 3 0 0 9 3 processes for coal and minerals 4 FME221 Particle technology (ESO 3 0 0 9 3 1) 5 E/SO 2 E/SO 3 0 0 9 3 6 FMC251 Particle technology 0 0 2 2 2 laboratory 7 FMC252 Physical separation 0 0 2 2 2 processes laboratory Total Credit 49 19

SEMESTER IV S. Subject Subject Name Lecture Tutorial Practical Credit Contact No. ID (L) (T) (P) Hours Hours 1 FMC204 Electrochemistry and 3 0 0 9 3 corrosion 2 FMC205 Thermodynamics and 3 0 0 9 3 kinetics 3 FMC206 Phase transformation and 3 0 0 9 3 heat treatment 4 FMC207 Fine particle processing for 3 0 0 9 3 coal and minerals 5 FME222 Introduction to fuel 3 0 0 9 3 technology (ESO 3) 6 FMC253 Fine particle processing 0 0 2 2 2 laboratory 7 FMC254 Introduction to fuel 0 0 2 2 2 technology laboratory Total Credit 49 19

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SEMESTER V S. Subject Subject Name Lecture Tutorial Practical Credit Contact No. ID (L) (T) (P) Hours Hours Coal and process 1 FMC301 3 0 2 11 5 equipment selection 2 FMC302 3 0 0 9 3 3 OE1 Open Elective 3 0 0 9 3 4 HSS1 HSS 3 0 0 9 3 5 E/SO4 ESO 3 0 0 9 3 6 Extractive metallurgy 0 0 3 3 3 FMC351 laboratory Total Credit 50 20

SEMESTER VI S. Subject Subject Name Lecture Tutorial Practical Credit Contact No. ID (L) (T) (P) Hours Hours 1 FMC303 Mechanical metallurgy 3 0 0 9 3 2 FMC304 Coal and mineral 3 0 2 9 5 processing plant design 3 MS1 MS 3 0 0 9 3 4 OE2 OE 3 0 0 9 3 5 OE3 OE 3 0 0 9 3 6 FMC352 Heat treatment and 0 0 3 3 3 mechanical metallurgy laboratory 7 FMC391 Industrial Tour 0 0 0 0 0 Total Credit 48 20

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SEMESTER VII S. Subject Subject Name Lecture Tutorial Practical Credit Contact No. ID (L) (T) (P) Hours Hours 1 DE2 Dept. Elective 3 0 0 9 3 2 DE3 Dept. Elective 3 0 0 9 3 3 OE4 OE 3 0 0 9 3 4 OE5 OE 3 0 0 9 3 5 OE6 OE 3 0 0 9 3 6 UGP UGP-1 (Zero-Credit Compulsory) 0 0 0 0 3 7 DC12* Internship/Training/Seminar/Field- 0 0 0 0 3 Excursion Total Credit 45 21

SEMESTER VIII S. Subject Subject Lecture Tutorial Practical Credit Contact No. ID Name (L) (T) (P) Hours Hours 1 DE4 Dept. 3 0 0 9 3 Elective 2 DE5 Dept. 3 0 0 9 3 Elective 3 OE7 OE 3 0 0 9 3 4 DC13* UGP-2 0 0 0 9 3 5 HSS/MS HSS/MS 3 0 0 9 3 Total Credit 45 15

*Internship and Training shall start after the IV Semester, from Summer/winter vacation for at least 12 weeks before graduation and Viva–Voce for the internship shall be held at the beginning of each subsequent semester beginning with V Semester, while the project will continue up to the end of the VIII Semester.

Note: 1. OE allotment to be based on CGPA up to previous semester, Total strength of students to be decided by the Dept/Teacher concerned.

2. In place of practicals, a few courses with tutorials can be offered by the Department.

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SUBJECT LIST DEPARTMENT CORE S. Subject Subject Name Lecture Tutorial Practical Credit Contact No. ID (L) (T) (P) Hours Hours 1 FMC201 Colloids and interfacial phenomena 3 0 0 9 3 2 FMC202 Heat and mass transfer 3 0 0 9 3 FMC203 Physical separation processes for coal and 3 0 0 9 3 3 minerals 4 FMC204 Electrochemistry and corrosion 3 0 0 9 3 5 FMC205 Thermodynamics and kinetics 3 0 0 9 3 6 FMC206 Phase transformation and heat treatment 3 0 0 9 3 7 FMC207 Fine particle processing for coal and minerals 3 0 0 9 3 8 FMC301 Coal and mineral process equipment selection 3 0 2 11 5 9 FMC302 Extractive metallurgy 3 0 0 9 3 10 FMC303 Mechanical metallurgy 3 0 0 9 3 11 FMC304 Coal and plant design 3 0 2 11 5

PRACTICAL 1 FMC251 Particle technology laboratory 0 0 2 2 2 2 FMC252 Physical separation processes laboratory 0 0 2 2 2 3 FMC253 Fine particle processing laboratory 0 0 2 2 2 4 FMC254 Introduction to fuel technology laboratory 0 0 2 2 2 5 FMC351 Extractive metallurgy laboratory 0 0 3 3 3 6 FMC352 Heat treatment & mechanical metallurgy 0 0 3 3 3 laboratory

DEPARTMENT ELECTIVES (offered by FMME) 1 FMD461 Computational techniques and modelling 3 0 0 9 3 2 FMD462 Process control and plant layout 3 0 0 9 3 3 FMD463 Non-ferrous extractive metallurgy 3 0 0 9 3 4 FMD464 Mineral policy and economics 3 0 0 9 3 5 FMD525 Iron and steel making 3 0 0 9 3 6 FMD526 Cement technology 3 0 0 9 3 7 FMO543 Waste processing and management 3 0 0 9 3 8 FMO544 Clean coal technology 3 0 0 9 3 9 FMO545 Equipment design 3 0 0 9 3

OPEN ELECTIVES (offered by FMME) 1 FMO431 Elements of mineral engineering 3 0 0 9 3 2 FMO541 Characterization of materials 3 0 0 9 3

ESO (offered by FMME)

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1 FME221 Particle technology 3 0 0 9 3 2 FME222 Introduction to fuel technology 3 0 0 9 3

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Course Contents

COLLOIDS AND INTERFACIAL PHENOMENA Course Course Name of Course L T P Credits Type Code DC FMC201 Interfacial phenomena 3 0 0 9

Course Objective Fundamentals of colloids and interfacial phenomena and its applications in mineral and metals processing. Learning Outcomes • Characterization of colloidal systems and interfaces. • Fundamentals, characterization, and applications of liquid-gas, liquid-liquid, solid-gas, solid-liquid, and charges interfaces. • Interactions between colloidal particles and factors resulting in colloidal stability. • Experimental techniques for characterization of interfaces and colloidal systems. • Applications of colloids and interfacial phenomena in industrial applications with special emphasis on mineral and metals processing operations.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Colloidal systems: definition; importance; particle Introduction to colloids and characterization; classification of colloidal systems; characterization of particles 1 structural characteristics; motion of particles in liquid 3 constituting colloidal systems media: viscosity, sedimentation, Brownian motion, diffusion; osmotic pressure. Liquid-gas and liquid-liquid interfaces: surface and Concept of surface and interfacial interfacial tension; Kelvin’s equation; measurement of tensions, effect of curvature and surface and interfacial tensions; adsorption at interface; temperature on surface tension, 2 6 surfactants; Gibbs adsorption equation; micelle measurement of surface tension, formation; critical micelle concentration; spreading; adsorption at interfaces, introduction monomolecular films; emulsions and foams. to emulsions and foams. Solid-gas interface: Adsorption of gases on solids; Modes of adsorption of gases on physical versus chemical adsorption; classification of solids, adsorption isotherms, physical adsorption; Langmuir, Freundlich, and BET characterization of porous solids. 3 6 adsorption isotherms; determination of total surface area of porous solids, heat of adsorption; effect of solid structure and composition on adsorption. Solid-liquid interface: Contact angle and wetting; Introduction, characterization, and Young’s equation; spreading, adhesion, and immersion mechanisms of wetting phenomenon. 4 6 wetting; measurement of contact angle; flotation; detergency; adsorption from solution. Charged interfaces: Electric double layer; zeta Fundamentals, characterization and potential; electrokinetic phenomena: electrophoresis, applications of electric double layer. 5 6 electroosmosis, streaming potential, sedimentation potential; Smoluchowski and Huckel equation. Colloidal interaction and stability: van der Waals Aggregation and stability of colloidal 6 interaction; DLVO theory; electrostatic and steric 3 dispersions. interactions; flocculation.

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Methods to characterize colloidal systems: Experimental techniques for 7 Viscometry, microelectrophoresis, sedimentation, 3 characterizing colloidal systems. surface tension; static and dynamic light scattering. Industrial applications of colloids and interfacial Industrial applications of colloids and 8 6 phenomena especially in minerals, metals processing. interfacial phenomena. Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Introduction to colloid and surface chemistry Duncan J. Shaw Butterworth-Heinemann

HEAT AND MASS TRANSFER Course Course Name of Course L T P Credit Type Code DC FMC202 Heat and Mass Transfer 3 0 0 9

Course Objective Fundamentals of transport phenomena and its application in metals processing Learning Outcomes Governing equations for solving microscopic and macroscopic problems related to fluid flow, heat and mass transfer with applications in metals processing.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Viscous properties of fluids, momentum equation for solving Fluid mechanics: Continuity equation; Navier-Stokes laminar flow problems, introduction equation; turbulence; Engineering Bernoulli’s 1 8 to turbulence, mechanical energy equations; hydrocyclone; electrostatic precipitator; balance equation for solving supersonic flow in nozzles; Darcy’s law macroscopic flow problems, flow in porous media. Heat transfer: Steady and unsteady conduction; General Mechanism for transport of thermal heat transfer equation; natural and forced convection; energy, equations governing heat heat transfer in turbulent flows; heat transfer transfer by conduction, convection, 2 coefficient; Newtonian cooling; radiation heat transfer; 17 and radiation, macroscopic treatment packed and fluidized beds; phase transformation; of heat transfer, applications in metals solidification of metals; heat exchanger design; furnace processing. design Solid state diffusion: Diffusive and convective fluxes; Mechanism of diffusion in solids, diffusion mechanisms; diffusion coefficient; Kirkendall governing equations for solid state 3 effect; uphill diffusion; steady and unsteady diffusion; 8 diffusion, applications in physical estimation of diffusion coefficients; Carburization; metallurgy. phase transformation; homogenization of alloys Convection mass transfer: Natural and forced Governing equations for mass transfer convection mass transfer; general mass transfer in fluid systems, macroscopic 4 equation; diffusion through stagnant and moving gas 5 treatment of mass transfer, real-life film; chemical vapour deposition; mass transfer applications. coefficient and its applications; degasification Interphase mass transfer: Two-resistance mass transfer Chemical reaction coupled mass 5 theory; mixed control reactions; oxidation of metals; 2 transfer between two phases vaporization

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Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Transport phenomena in metals D. R. Poirier, G. H. Springer International 1 processing Geiger Publishers 2 Engineering in process metallurgy R. I. L. Guthrie Oxford University Press Elements of chemical reaction 3 H. Scott Fogler Prentice Hall engineering

PHYSICAL SEPARATION PROCESSES FOR COAL AND MINERALS Course Course Name of Course L T P Credits Type Code DC FMC203 Physical separation processes for coal and minerals 3 0 0 9

Course Objective To learn about the principles, construction and operation of physical separation processes Learning Outcomes Upon successful completion of this course, students will have the • knowledge of the need, scope and applications of density separation • understanding of the basic principles of density separation • familiarisation with the different techniques used for thedensity separation of coal and minerals • knowledge of the important factors that affect the performance of industrial density separation technologies • knowledge about the performance assessment of density separators and their benchmarking

Unit Lecture Topics to be Covered Learning Outcomes No. Hours Introduction to physical separation processes: Basic Introduction to the subject, the Principles of Separation Processes; different types of different concentration techniques and processes employed in mineral engineering: density, their scopes, applications and magnetic, electrical, surface, optical separations. limitations. Introduction to the basic 1 3 coal/ore characteristics required for applying these terminology related to concentration, processes. Calculations of yield, recovery, ratio of general calculations related to concentration, enrichment ratio and separation concentration efficiency. Washability analysis:Sink-float test-work for coal and Knowledge of the washability 2 3 minerals and data interpretation. analysis test-work Jigging: Principles of jigging including the major Knowledge of the applications and phenomena, equal settling/jigging particles, v-t curves, basic principles involving industrial 3 jig cycles and their applications, different types of jigs- 5 jigging, its operation and performance mechanical and pneumatic jigs their merit and demerits, optimisation variables affecting jigging Dense medium separation: Principles of dense medium Awareness of the different dense separation, stability of media suspension, preparation of medium separation techniques and dense medium, types of solids and their properties to use their application, construction, as dense medium. Factors affecting dense medium operation and performance 4 stability and consistency. Different types of static and 7 determining factors. Knowledge of dynamic separators e.g, Dense Medium Baths (deep and the need of a medium recovery circuit shallow) and Dense Medium Cyclones, Vorsyl and its general layout Separator, Tri-flo separator etc., typical media preparation and media recovery equipment and circuits

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Stub-cyclones, Teetered Bed Separators, Reflux Familiarisation with the different Classifiers: Construction, operation and applications. techniques used for the gravity Flowing film concentration: Principles. Tabling, concentration of intermediate size 5 influence of various factors affecting tabling, 5 particles, with their construction, mathematical analysis, different types of tables. Spiral operation and performance concentration, application of spiral concentrators, optimisation Reichert’s cone Enhanced gravity concentration: Different gravity Knowledge of the gravity separation 7 concentrators like multi-gravity separator, Knelson 2 techniques applied for the concentrator, Kelsey jig, Falcon separator etc. concentration of fine particles Performance analysis of density separators: Comprehension of the procedure Estimation of cleaning performance, calculation of applied for the performance 8 performance parameters: cut-density, EP, Error area, 3 assessment of density separators and imperfection organic efficiency, ash reduction factor, interpretation of the results yield reduction factor, etc. Magnetic Separation: Principles of magnetic 7 Learning of the principles, separation, types of magnetic materials; construction, construction, operation and important 9 operation and performance factors of different magnetic factors for magnetic separation separators; typical applications equipment Electrical Separation: Principles of electrostatic 4 Understanding the principles of separation. Electrical properties of materials. Lifting and electrical separation and knowledge pinning effect, corona discharge. Construction, of the construction, operation and 10 operation and performance factors of different electrical important factors of electrical separators. Auxiliary equipment. Multi roll separator, separators plate and screen separators, ESP, tribo-electric separator Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Barry A. Wills James 1 Wills' Mineral Processing Technology Butterworth-Heinemann Finch Society for , Metallurgy and 2 Coal Preparation Joseph W. Leonard III Exploration Coal Preparation Technology. Volume 3 D. G. Osborne Graham and Trotman 1 and 2. Magnetic methods for the treatment of 4 J. Svoboda Elsevier minerals Reference Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Mineral Processing Design and 1 A. Gupta and D.S. Yan Elsevier Operation: An Introduction Errol G. Kelly, David J. 2 Introduction to Mineral Processing Wiley Spottiswood Gravity Concentration Technology 3 Richard O. Burt, Chris Mills Elsevier (Developments in Mineral Processing, 5) Society for Mining, SME Mineral Processing and Extractive Robert C. Dunne, S. Komar 4 Metallurgy and Metallurgy Handbook Kawatra, Courtney A. Young Exploration 5 High Gradient Magnetic Separation Richard Gerber, Robert R. Birss Research Studies Press

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PARTICLE TECHNOLOGY Course Course Name of Course L T P Credits Type Code ESO FME221 Particle Technology 3 0 0 9

Course Objective The objective of the course is to learn about the fundamentals of particle characterisation, and classification and get familiarised with the different technologies used, with focus on the equipment, their construction, operation and performance optimization Learning Outcomes Upon successful completion of this course, students will have • the knowledge about the sampling principles and methods as required for various analyses • the knowledge of the various properties of particles and their characterisation • the understanding of the importance and application of comminution and classification operations in industry • the understanding about the underlying principles and phenomena of all relevant size reduction and size separation units used in the industry • the knowledge of the construction, operation, application and performance enhancement of industrial size reduction and size separation equipment • the information about the performance analysis methodologies and mass and water balancing of industrial comminution-classification circuits

Unit Lecture Topics to be Covered Learning Outcome No. Hours Introduction: definition of mineral, rock, ore, , Familiarisation with the fundamentals tenor. Unit operations, conceptual flow diagram to of mineral engineering 1 2 represents sequence of material in plants. Particle properties and their relevance to mineral processing Sampling: Definition, need, methods of sampling Knowledge of the principles and (solids and slurries), Gy’s law of sampling, estimation standard methods used for the 2 2 of minimum amount of sample required, BIS standard collection of solid, liquid and slurry for sampling, accurate sampling of solids and slurry samples Particle size and size distribution: Geometrical Knowledge of the concept of size and diameters, equivalent or derived diameters, statistical its different definitions and of the diameters to designate the size of the irregular various methods applied for their particles, in sieve and sub-sieve sizes, and their measurement, representation and measurement techniques 3 3 interpretation of size distribution data Particle size distribution and quantification, different methodologies Size distribution functions: Gaudin-Schumann, Rosin-Rammler, Gaudin-Meloy, Broadbent and Calcott Surface area and shape measurement: Direct and Knowledge of the various methods indirect methods, permeability, gas adsorption, applied for the measurements of surface 4 2 Volume and porosity measurements, Bulk solids area and shape of particles and other properties – bulk density, true density. bulk properties Basics of size reduction: Fundamentals of size Understanding of the meaning, scope reduction, modes of fracture comminution laws, drop and importance of comminution and 5 shatter tests and shatter index, single particle breakage 3 mechanism of comminution, with and packed bed breakage; basic principles of crushing knowledge of the relevant material and grinding. grindability indices testing techniques Crushing: Construction & operational features of Familiarisation with the different 6 7 different : objectives, forces of breakage; crushing equipment used in the

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design, operation and maintenance of jaw, gyratory, industry, their construction, operation, cone, single and double roll , sizers, hammer merits, demerits, operational and design mills, ring granulators and rotary breakers, high parameters and their performance compression rolls. performance aspects. in-pit and analysis portable crushers. Grinding: Principles, construction & operational Familiarisation with the different features of grinding mills: ball, rod, pebble, milling equipment and techniques used autogenous, sag and fluid energy mills, mills used in in minerals, power and cement 7 power plants and cement industry; liners; feed 7 industries, their construction, operation, entry and product discharge mechanisms; open- and merits, demerits, and operational and closed-circuit grinding; application of mills; effect of design parameters process parameters on mill performance Industrial screening: need and importance of size Understanding the principles and separation, fundamentals of industrial screening; dry mechanism, need and scope of and wet screening; classification of screens; different screening and knowledge about the 8 types of industrial screens. pre-scrubbing and other 5 different types of industrial screens, processes to improve screening efficiency. Screen their applications, construction, performance measurement, factors affecting screen operation, important factors and performance. performance analysis Classification: Settling of solids in fluids, settling Understanding the principles of velocities for Stokesian and Newtonian conditions, classification in fluids and Reynolds number and its application, settling ratios. familiarisation with the different 9 Different types of classifiers used in mineral industry: 8 industrial classifiers, their construction, Hydrocyclones, Mechanical Classifiers, Efficiency of operation, important factors, classifiers; Solids and water balance calculations. performance analysis and circuit balancing Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Wills' Mineral Processing Technology Barry A. Wills James Finch Butterworth-Heinemann 2 Introduction to Mineral Processing Errol G. Kelly, David J. Spottiswood John Wiley and Sons Reference Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Mineral Processing Design and 1 A. Gupta and D.S. Yan Elsevier Operation: An Introduction Andrew L. Mular, Roshan Society of Mining 2 Mineral Processing Plant Design Boman Bhappu Engineers (AIME)

PARTICLE TECHNOLOGY LABORATORY Course Course Name of Course L T P Credit Type Code DC FMC251 Particle technology laboratory 0 0 2 2

Course Objective To impart practical exposure to the different particle characterisation and size reduction techniques Learning Outcomes After completion of the course, the students will have hands-on knowledge of • particle characterisation techniques • construction and operation of laboratory scale models of common industrial crushers

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• effect of different parameters on size reduction

Unit Practical Name of Experiment Learning Outcome No. Hours Sampling – methods and Knowledge of the different sampling methods and their 1 2 accuracy accuracy Knowledge of particle size distribution analysis through 2 Dry and wet sieving 2 sieving and understanding of the effect of water addition in sieving Relative density, bulk density Knowledge of the techniques used for the determination 3 2 Abrasion index determination of relative and bulk densities and abrasion index Sub-sieve size distribution Familiarisation with the process of sub-sieve size 4 2 analysis using Andreasen pipette analysis with Andreasen pipette Sub-sieve size distribution Familiarisation with the process of sub-sieve size 5 analysis using beaker decantation 2 analysis with beaker decantation method method Sub-sieve size distribution Familiarisation with the process of sub-sieve size 6 2 analysis using Cyclosizer analysis with Cyclosizer Understanding the construction and operation of a roll Roll crusher – importance of set 7 2 crusher and the effect of its set and the feed material on and feed material its performance Understanding the construction and operation of a jaw Jaw crusher – importance of type 8 2 crusher and the effect of its type and the feed material and feed material on its performance Effect of crusher type on Understanding of the difference in breakage 9 2 breakage of material characteristics of different crushers Grinding – effect of residence Understanding the construction and operation of a ball 10 2 time mill and the effect of residence time on its performance Grinding – effect of ball size Understanding the effect of ball size distribution on the 11 2 distribution grinding mill performance Understanding the effect of ball load on the 12 Grinding – effect of ball charge 2 performance of a

PHYSICAL SEPARATION PROCESSES LABORATORY Course Course Name of Course L T P Credit Type Code DC FMC252 Physical separation processes laboratory 0 0 3 3

Course Objective To obtain practical exposure to the different physical separation techniques used for the quality upgradation of coal and minerals Learning Outcomes After completion of the course, the students will have hands-on knowledge of • the technique used for assessing the potential of /coal for density separation • the workings of laboratory models of common industrial density separators • the technique used for characterising the magnetic content of an ore • the workings of laboratory models of common industrial magnetic separators

Unit Practical Name of Experiment Learning Outcome No. Hours

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Familiarisation with the methodology adopted for 1 Washability analysis 3 determining the potential and ease of density separation Effect of time on jigging Understanding the effect of time on jigging performance 2 3 performance Effect of feed solids Understanding the effect of feed solids concentration on 3 concentration on spirals 3 its performance performance Mozley mineral separator – effect Understanding the construction and operation of a jig 4 of wash water flow rate and 3 and the effect of wash water flow rate and oscillation oscillation amplitude amplitude on its performance Understanding the construction and operation of a Wilfley table – effect of wash 5 3 Wilfley table and the effect of wash water flow rate on water flow rate its performance Performance analysis of density Knowledge of the methodology of performance analysis 6 3 separator of density separators Understanding the construction and operation of a Davis’ tube magnetics test – 7 3 Davis’tube magnetics tester and the effect of magnetic effect of magnetic field intensity field intensity on the determination of magnetics content Understanding the construction and operation of a Induced roll magnetic separator – induced roll magnetic separator and the effect of 8 effect of magnetic field intensity 3 magnetic field intensity and roll speed on its and roll speed performance Understanding the construction and operation of a WHIMS – effect of field 9 3 WHIMS and the effect of magnetic field intensity and intensity and matrix type matrix type on its performance Understanding the construction and operation of a perm Perm roll magnetic separator- 10 3 roll magnetic separator and the effect of roll speed and effect of roll speed and feed rate feed rate on its performance Performance analysis of Knowledge of the methodology of performance analysis 11 3 magnetic separators of density separators

ELECTROCHEMISTRY AND CORROSION Course Course Name of Course L T P Credits Type Code DC FMC204 Electrochemistry and Corrosion 3 0 0 9

Course Objective Fundamentals of electrochemical cells and its applications in metals finishing, batteries, effluent treatment, and corrosion in metals and alloys Learning Outcomes • Thermodynamics and kinetics of electrochemical reactions. • Principles of electrochemical cell design. • Industrial applications: electrochemical metal finishing and effluent treatment. • Battery characteristics and components, types of batteries. • Fundamentals and types of corrosion and corrosion protection in metals.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Electrochemical cells;Faraday’s law; half-cell potential; EMF Knowledge of the 1 2 series; Nernst equation. thermodynamics of

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electrochemical reactions. Concept of overpotential; activation overpotential; exchange Understanding charge and mass current density; polarization diagram; mass transfer in transfer kinetics in 2 electrochemical systems; concentration overpotential; 10 electrochemical reaction and limiting current density; current distribution; principles of cell principles of cell design. design; electrochemical measurements. Electroplating of metals and alloys; electroless deposition; Principles and practice of metal 3 anodizing; electropolishing; electropickling; electrophoretic 6 finishing operations. painting; electroforming. Battery characteristics; battery components; types of Knowledge of the fundamentals 4 5 batteries: Pb-acid, Mn-C; lithium ion; fuel cells and types of batteries Eco-cell; fluidized bed electrode; electrodialysis; Principles and applications of 5 electrofiltration. 2 electrochemical effluent treatment. Principles of corrosion in metals and alloys; mixed potential; Fundamentals of corrosion, types of corrosion: galvanic corrosion, crevice corrosion, types of corrosion, principles 6 pitting corrosion, stress corrosion, intergranular corrosion, 12 and practice of corrosion high temperature corrosion; corrosion kinetics; corrosion protection protection Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Corrosion Engineering Mars G. Fontana McGraw Hill Education Reference Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Electrochemical Methods – Fundamentals 1 Allen J. Bard, Larry R. Faulkner John Wiley and Sons and Applications John O’M. Bockris, Amulya K. N. Kluwer Academic 2 Modern Electrochemistry Reddy Publishers

THERMODYNAMICS AND KINETICS Course Course Name of Course L T P Credits Type Code DC FMC205 Thermodynamics and Kinetics 3 0 0 9

Course Objective Basic understanding of the laws of thermodynamics and equilibrium in chemical/metallurgical systems and chemical reaction kinetics. Learning Outcomes • Laws of thermodynamics and its applications, equilibrium in chemical reactions, phase equilibria in one and two component systems. • Rate law in chemical reaction kinetics, definition and basic design of ideal and non-ideal reactors.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Thermodynamics Importance of thermodynamics; basic definitions: universe, Introduction to 1 2 system, surroundings, boundary, homogeneous and thermodynamics and

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heterogeneous systems, intensive and extensive properties, state associated terminology. and path functions, classification of processes, zeroth law of thermodynamics; equations of state; mixture of ideal gases; real gases. Work and heat; state and path functions; reversible and Concepts and applications irreversible processes; first law of thermodynamics; internal related to the first law of 2 4 energy; enthalpy; isothermal and adiabatic expansion; Joule- thermodynamics. Thomson expansion; examples of some thermodynamic cycles Second law of thermodynamics; heat engines; Carnot cycle; Concepts and applications concept of entropy; criterion for equilibrium; entropy and related to the second law of 3 7 disorder; Gibbs free energy; Maxwell’s relations; Gibbs- thermodynamics and criteria Helmholtz equation for equilibrium. Calculation and measurement Heat of formation; heat of reaction; heat capacity; Hess’s law; of enthalpy changes in 4 3 third law of thermodynamics; calorimetry endothermic and exothermic reactions. Multicomponent systems; partial molar quantities; chemical Concepts related to 5 potential; Gibbs-Duhem equation; homogeneous and 4 equilibrium in heterogeneous chemical equilibrium multicomponent systems. One-component phase equilibria: phase diagram; Gibbs phase Understand phase transition 6 rule; Clayperon equation; critical point and supercritical fluids; 2 and phase co-existence in a Clausius-Clayperon equation one-component system Two-component phase equilibria: Ellingham diagram; Raoult’s Understand phase equilibrium 7 law; Henry’s law; concept of activity, Gibbs-Duhem equation, 7 in gas-solid and gas-liquid regular solution, phase diagram, Lever’s rule; Sievert’s law systems Chemical Kinetics Thermodynamics versus kinetics; reaction mechanism in Fundamentals of chemical homogeneous and heterogeneous systems; rate controlling step; reaction kinetics and its rate equation; experimental determination of rate equation application in ideal/non-ideal 8 10 parameters; batch and continuous reactors; stirred tank reactors; reactors plug flow reactors; reactor conversion and sizing; residence time distribution. Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Lecture Notes | Thermodynamics & Kinetics | Chemistry | Massachusetts MIT OpenCourseWare Massachusetts Institute 1 Institute of (https://ocw.mit.edu/courses/chemistry/5-60-thermodynamics- of Technology Technology kinetics-spring-2008/lecture-notes/) David R. Gaskell, 2 Introduction to the Thermodynamics of Materials CRC Press David E. Laughlin 3 Elements of chemical reaction engineering H. Scott Fogler Prentice Hall

PHASE TRANSFORMATION AND HEAT TREATMENT Course Course Name of Course L T P Credit Type Code DC FMC206 Phase transformation and heat treatment 3 0 0 9

Course Objective Principles of phase transformation and heat treatment with emphasis on steels and non-ferrous alloys

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Learning Outcomes • Crystal structure in metals. • Thermodynamics and kinetics of solid-liquid and solid-solid phase transformations. • Phase diagrams and microstructure evolution in solid-liquid and solid-solid transformations. • Heat treatment techniques in for modification of mechanical properties Fe-C systems (steels) and non-ferrous metals.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Types of bonding; lattice and unit cell; crystal systems and Introduction to atomic 1 Bravais lattices; atomic packing; voids; Miller indices 2 bonding and crystal structure Gibbs free energy vs. composition diagram; types of binary phase Phase diagrams in metallic 2 4 diagrams; Lever’s rule; phase rule systems Thermodynamics of solidification; nucleation and growth; pure Thermodynamics, metal solidification; alloy Solidification: redistribution of solute microstructure, and 3 6 during solidification; constitutional under-cooling; dendrites applications of solid to growth; structure of casting and ingots; types of casting liquid transformation Solid state phase transformation: nucleation and growth; overall Thermodynamics and 4 transformation rate 3 kinetics of solid state phase transformation Iron-carbon alloy system: iron-Fe3C diagram; nucleation and Phase diagram and 5 growth of pearlite; cooling of hypo-eutectoid; eutectoid; and 3 microstructure in iron- hyper-eutectoid steels; types and microstructure of cast iron carbon alloy system JMKA (Avrami) kinetics; TTT and CCT Diagrams; bainitic Kinetics of solid-state 6 transformation; martensitic transformation 3 transformation in iron- carbon system Annealing; normalizing; hardening; tempering; Heat treatment processes of 7 recovery/recrystallization/grain growth; hardenability of steels 3 steel (Jominy end quench method) Effect of alloying elements 8 Role of alloying elements in steels 2 on phase transformation in steels. Thermomechanical treatment of steels: controlled rolling; hot-cold Thermomechanical 9 3 rolling; ausforming; isoforming treatment of steels Heat treatment of aluminium alloys: designations; aluminium Fundamentals of heat alloy series; heat treatable and non-heat treatable alloys; treatment of non-ferrous 10 precipitation and sequence; effect of deformation and temperature; 5 alloys heat treatment of titanium and magnesium alloys; heat treatment of titanium and magnesium alloys Carburizing; nitriding; carbonitriding; laser surface cladding; Surface hardening methods 11 3 flame hardening; induction hardening Batch Furnaces; continuous furnaces; salt bath furnaces; Furnace and controls used 12 Temperature measurement and control: calibration; thermocouples 2 in heat treatment and pyrometers Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. 1 Solid-State Phase Transformations V. Raghavan, Morris Cohen Plenum Press New Age 2 Principles of Heat Treatment of Steel R. C. Sharma International 3 Heat Treatment: Principles and T. V. Rajan, C. P. Sharma, Ashok Prentice Hall

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Techniques Sharma

FINE PARTICLE PROCESSING FOR COAL AND MINERALS Course Course Name of Course L T P Credits Type Code DC FMC207 Fine particle processing for coal and minerals 3 0 0 9

Course Objective To give idea of various mineral processing techniques at fine particle size and idea of dewatering technology. Learning Outcomes Upon successful completion of this course, students will: • be able to acquire the knowledge about the processing of particles at fine size range. • be able to dewater the wet materials generated from mineral processing plants.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Understanding of basic approach 1 Introduction: Fundamentals of fine particle processing. 3 for selection of process based on the properties of material. : Flotation theory, flotation reagents, This unit will help student in laboratory flotation tests. Types of flotation: emulsion understanding the beneficiation of flotation, carrier flotation, selective flotation, floc-flotation, fine particles based on the surface 2 skin flotation, reverse flotation, electro flotation. Flotation 15 properties. machine features and functions. Design, selection and sizing. Conventional and modern flotation machines - Column flotation, Jameson Cell etc. This will help students in Oil agglomeration: Principles, process equipment, selecting the process and 3 4 practices, reagents and application equipment related to oil agglomeration process. This will enable students to select Fluidization: Principles, process equipment and practices 4 2 process related to fluidization for Applications of fluidisation the processing of fines. This will help students to understand the behaviour of Flocculation and selective flocculation: Principles, process 5 4 particles in liquid to define the equipment, practices, reagents, and their selection process of dewatering and selective flocculation. Thickening and filtration: Thickening fundamentals, basic machine features, different types of thickeners – conventional thickener, high rate thickener, lamella This will help student to thickener, deep cone thickener, paste thickening technology understand the separation of 6 9 etc. Filtration principles, constant rate and constant pressure liquid from slurry i.e. dewatering filtration, filters – vacuum drum filter, vacuum disc filter, related processes. filter press, horizontal belt filter. Design, selection and sizing of thickeners and filters Knowledge of the principles and 7 Drying: Principles and methods 2 practice of industrial drying Text Book: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Mineral Processing Design and Operation: An Introduction A. Gupta and D.S. Yan Elsevier

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Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Introduction to Mineral Processing Errol G. Kelly, David J. Spottiswood John Wiley and Sons 2 Principles of Mineral Dressing Antoine Marc Gaudin Tata McGraw Hill Unit Operations of Chemical Warren L. McCabe, Julian C. Smith, 3 McGraw Hill Engineering Peter Harriott Perry's Chemical Engineers' 4 Don W. Green, Marylee Z. Southard McGraw Hill Handbook Butterworth- 5 Solid-Liquid Separation Ladislav Svarovsky Heinemann

INTRODUCTION TO FUEL TECHNOLOGY Course Course Name of Course L T P Credits Type Code DC FME222 Introduction to fuel technology 3 0 0 9

Course Objective The main aim of the course is to give an introduction to the different types of fossil fuels. The emphasis of the course will be on the characterizations and utilizations of solid fuels, basics of liquid and gaseous fuels. Learning Outcomes At the end of this course students would have the knowledge of • coal characterisation and its utilisation in different thermochemical conversion processes • design of coal utilisation equipment • biomass characterisation and utilisation.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Introduction to energy resources, Indian perspective, Origin and Students will get 1 formation of coal: Different theories on coal formation, Rank of 3 overview of energy coal, classification of coal. resources, including coal Coal Properties: Chemical, Physical and Plastic properties: Students will learn Proximate analysis, Ultimate analysis, coal petrography, Gross various characterization calorific value, Net calorific value, Free Swelling Index, Caking techniques for coal 2 Index, Roga Index, LTGK, plastometer, dilatometer, Estimation of 10 total moisture. Hardness, determination of HGI. Porosity, density, specific heat, thermal conductivity, Selection of coal for various processes. Behaviour of coal at elevated temperature. Fundamental and Knowledge on mechanism of coal carbonization, Types of carbonization and fundamentals of coal 3 5 processes, Coke properties, Formed coke, bi-products of coal carbonization. carbonization. Fundamentals of coal combustion, mechanism of combustion, Knowledge on coal 4 different coal firing systems, stoichiometric calculations.Clean coal 6 combustion. technology for power, cement and steel industries. Design of coke ovens, coal combustion and gasification systems. Knowledge on design of Classification and selection of refractories. Fuel and heat losses in coal utilization 5 7 combustion and carbonization units. equipment, selection of refractories 6 Biomass and its utilization: types of biomass, biomass utilisation 4 Knowledge on biomass,

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process, Production of biochar, bio oils/fuel for various industrial waste materials as fuel. applications, Utilization of various waste materials as fuel, Fuel cell. Introduction to fuel cell Classification of crude petroleum, characteristics of petroleum and Introductory knowledge their products. Classification of gaseous fuels, production of on liquid and gaseous 7 gaseous fuel from coal. Liquefaction of coal, other utilization 4 fuel potential of coal. CBM/CMM, Gas hydrates, shale gas

Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Fuels and Combustion Samir Sarkar Universities Press Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Elements of Fuels, Furnaces & Refractories O. P. Gupta Khanna Publishers 2 Fuels, Furnaces and Refractories R. C. Gupta Prentice Hall 3 The Chemistry and Technology of Coal James P. Speight CRC Press

FINE PARTICLE PROCESSING LABORATORY Course Course Name of Course L T P Credit Type Code DC FMC253 Fine particle processing laboratory 0 0 2 2

Course Objective To give practical knowledge of processing of coal and minerals at fine size range. Learning Outcomes Upon successful completion of this course, students will: • have the practical experience of processing of fines. • be able to understand the practical application of flocculation, thickening and filtration process in dewatering of fines.

Exp. Description Practical Learning Outcome No. Hours 1 Processing of copper ores using froth flotation 2 Understanding of beneficiation of sulphide and study the effect of collector dosage on ores using froth flotation technique and its flotation kinetics. kinetic behaviour.

2 Processing of lead-zinc ores using froth 2 Understanding of beneficiation of sulphide flotation and study the effect of frother dosage ores using selective froth flotation. on grade and recovery.

3 Processing of coal fines using froth flotation 2 This will help students in selecting in and study the effect of pulp density on the optimizing the reagent dosage and selecting quality of clean coal. flotation cell size.

4 Processing of iron ore fines using selective 2 This will help students to understand the flocculation and study the effect of reagent application of selective flocculation in dosage on the performance. beneficiation.

5 Study of the effect of oil dosage on the 2 This will help student to understand use of oil processing of coal/mineral using oil agglomeration in fines beneficiation.

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agglomeration.

6 Processing of ore/coal fines using advanced 2 This will give exposure of advanced gravity gravity separation technique. separation of fines.

7 Study the effect of process parameters (pH, 2 The students shall be able to understand the pulp density, flocculant dosage) on the settling dewatering of fines in coal washery and role and thickening behaviour of coal fines at given of process parameters. flocculant dosage.

8 Study the effect of process parameters (pH, 2 The students shall be able to understand the pulp density, flocculant dosage) on the settling dewatering of minerals in process plants and and thickening behaviour of iron ore fines. effect of process parameters. 9 Dewatering of fines using vacuum/pressure 2 This will give idea of filtration and its use in filtration. dewatering of fines.

10 Demonstration of laboratory model vacuum 2 This will give comparative idea of application drum filter and vacuum disc filter. of filters in dewatering of fines.

11 Demonstration of laboratory model thickener 2 This will give idea of application of and pressure filter. dewatering of fines using various equipment.

Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Laboratory Experiments in Mineral S. Venkatachalam, S. N. Oxford & IBH 1 Engineering Degaleesan Publishing Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Analytical methods for ores and minerals B. H. Khawas I.K. International Publishing House

INTRODUCTION TO FUEL TECHNOLOGY LABORATORY Course Course Name of Course L T P Credit Type Code DC FMC254 Introduction to fuel technology laboratory 0 0 2 2

Course Objective The main aim of the course is to give practical exposure of coal and other fuel characterization techniques and their significance. Learning Outcomes At the end of this course students should able to characterize fuel based on their properties and their significance during utilization.

Exp. Practical Name of Experiment Learning Outcome No. Hours 1 Ultimate Analysis of coal. 2 Elemental analysis of coal Proximate analysis of thermal coal Determination of ash, moisture, volatile matter and 2 2 fixed carbon contentsin coal 3 Free Swelling Index of coal 2 Swelling characteristics of coal 4 Caking index of coal 2 Caking and binding properties of coal

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5 LTGK of coal 2 Coking properties of coal at low temperature 6 GCV of fuel 2 Heating values of fuel Comparative proximate analysis Property changes during carbonisation 7 2 of coal and coke 8 HGI of coal 2 Grindability of coal 9 Characterisation of liquid fuels -I 2 Measurement of cloud point, pour point, smoke point, 10 Characterisation of liquid fuels -II 2 flash point and fire point of liquid fuels

COAL AND MINERAL PROCESS EQUIPMENT SELECTION Course Course Name of Course L T P Credit Type Code DC FMC301 Coal and mineral process equipment selection 3 0 2 11

Course Objective The objective of the course is make students capable of selecting right equipment through worked out examples. Learning Outcomes Upon successful completion of this course, students will: • be made familiar with various fundamentals and guidelines for equipment selection • be able to do the selection and sizing of coal and mineral processing equipment for size reduction, separation and quality upgradation • be made familiar with costing and performance evaluation of the process equipment

Unit Lecture Topics to be Covered Learning Outcome No. Hours Introduction: various methodologies involved in Students will learn about various 1 selection and sizing of various coal preparation and 2 methodologies for selection and mineral processing equipment sizing of processing units Equipment capacities: Definitions of equipment Fundamentals of equipment, capacities: Broad guidelines for equipment specifications capacities and flowsheets along required in tendering processes in coal preparation and with costing and purchase 2 2 mineral processing, Equipment symbols: Standard Process equipment symbols as per BIS norms. Crushers: Selection and sizing of reciprocating and non- Selection and sizing of various size reciprocating crushers, such as roll crushers and impact reduction units including primary, group of crushers for coal application and reciprocating secondary and tertiary crushers 3 crushers, such as jaw, gyratory and cone crushers for ore 6 through data based problem solving application Selection of rotary breaker for application in coal preparation Selection and sizing of rod, SAG and ball mills including Selection and sizing of various dry 4 re-grinding mills for metallic and non-metallic ores 5 and wet grinding units through data based problem solving Selection and sizing of industrial screens used in coal Selection and sizing of various size preparation and mineral processing separation units including industrial 5 Selection and sizing of hydrocyclones including 5 screens, mechanical and limitations involved; General overview of selection hydrocyclones through data based criteria for mechanical classifiers problem solving Application of probable error in separation, imperfection, Estimation and application of 6 4 organic efficiency NGM, cut-density, capacity, feed size, various technical and economic

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OPEX, CAPEX, yield reduction factor etc. (as applicable) parameters in selection of density in selection of density separators. separators Capacity estimation and selection of density separators Selection and capacity estimation of used in metallurgical and thermal coal preparation density separators for coal. 7 including specific numerical examples as class work and 7 Learning the rationale to make right as home work; Choice between Jigs, Dense Media Baths, choice of density separator. Drums and Cyclones; Application of spirals and WOC. Selection of different types of froth floatation cells Learn about selection of flotation (mechanical, Jameson, column, pneumatic, etc.) cell and estimation of banks and Estimation of number of banks and cells per bank for cells per bank for various ores and 8 4 flotation of coal and minerals, such as limestone, minerals with the help of problems fluorspar, copper and lead – zinc ores, etc with specific numerical examples as class work and as home work General overview of selection criteria for magnetic and Learn about selection of magnetic 9 2 electrostatic separators and electrical separators Performance Guarantee Tests for equipment used in coal Learn about PGTsignificance and 10 2 preparation and mineral processing plants. its application in processing plants Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Andrew L. Mular, Roshan Society of Mining 1 Mineral Processing Plant Design Boman Bhappu Engineers (AIME) Mineral Processing Design and 2 A. Gupta and D.S. Yan Elsevier Operation: An Introduction Reference Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. 1 Process Selection in Extractive Metallurgy Peter C. Hayes Hayes Publishing Society for Mining, Mineral Processing Plant Design, Practice, Andrew L. Mular, Doug N. 2 Metallurgy and and Control: Proceedings. Volumes I & II. Halbe, Derek John Barratt Exploration

EXTRACTIVE METALLURGY Course Course Name of Course L T P Credit Type Code DC FMC302 Extractive Metallurgy 3 0 0 9

Course Objective Introduction to unit operations used in the pyro/hydro-metallurgical extraction of metals from ore concentrates Learning Outcomes • Typical flowsheets in pyro/hydro-metallurgical metal extraction route. • Unit operations used in preliminary pyroprocessing and pyro/hydro-metallurgical processing of ore concentrates for extraction and purification of metals. • Typical flowsheets of some important non-ferrous metals.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Typical ore to metal flow sheet; brief introduction to Introduction and definition of 1 1 pyro/hydro-metallurgy, criteria for selecting and

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pyrometallurgy/hydrometallurgy route for metal extraction Drying. Gas-solid reactions;shrinking core model; Preliminary pyroprocessing of , , agglomeration,reduction reactions concentrate for subsequent 2 8 pyro/hydro metallurgy unit operations ; matte smelting; ; converting; Fundamentals of pyrometallurgy and vacuum/inert-gas degassing; zone ; fractional unit operations used for the 3 15 distillation;blast furnace, different zones in blast furnace, extraction and refining of metals blast furnace profile from concentrate ; types of leaching, Eh-pH diagrams and their Fundamentals of hydrometallurgy usefulness, chemical precipitation; cementation, solvent and unit operations used for recovery 4 extraction; ion exchange; aqueous and molten salt 12 of metals from aqueous solution and ; electrorefining; gaseous reduction of molten salts metals Typical flowsheets for extraction of metals such as Examples of flowsheets for the 5 3 copper, aluminium, magnesium extraction of important metals Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Process Selection in Extractive 1 Peter C. Hayes Hayes Publishing Metallurgy Affiliated East-West 2 Extraction of Nonferrous Metals H. S. Ray, R. Sridhar, K. P. Abraham Press First Course in Iron and Steel 3 Dipak Mazumdar Universities Press Making Unit Operations of Chemical Warren L. McCabe, Julian C. Smith, Peter 4 McGraw Hill Engineering Harriott

EXTRACTIVE METALLURGY LABORATORY Course Course Name of Course L T P Credit Type Code DC FMC351 Extractive Metallurgy laboratory 0 0 3 3

Course Objective The objective of the course is to provide the practical knowledge forextraction of metals from its ores. LearningOutcomes Upon successful completion of this course, students will: • Able to prepare raw materials for pyro metallurgical process • Able to extract metal from lean ore through hydrometallurgy route

Exp. Contact Name of experiment Learning Outcome No. Hours Effect of moisture content on the size and drop strength of Understanding the effect of green iron ore pellets with fixed binder and angle of 1 3 operation parameters of disc and inclination in a disc pelletizer and drum pelletizer. drum pelletizers

Effect of binder content on the size and drop strength of Effect of binders on properties of 2 iron ore pellet made with fixed moisture addition and 3 pellets angle of inclination in a disc pelletizer and drum

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pelletizer.

Effect of disc/drum speed on drop strength of green iron Effect of design/operational ore pellets with fixed binder, moisture content and angle 3 3 parameter on properties of pellets of inclination in a disc pelletizer and drum pelletizer.

Effect of time on leaching of copper sulphide ore, lead Understand the effect and 4 sulphide ore and zinc sulphide ore in sulphuric acid media 3 importance of leaching time

Effect of temperature on leaching of copper sulphide ore, Understand the effect and lead sulphide ore and zinc sulphide ore in sulphuric acid 5 3 importance oftemperature for media leaching

Effect of particle size on leaching of copper sulphide ore, Understand the effect and lead sulphide ore and zinc sulphide ore in sulphuric acid 6 3 importance of particle size for media leaching

Effect of leaching media on ore dissolution at fixed time, Effect and selection of leaching 7 temperature and particle size 3 media

Study the kinetics of roasting of ZnS by weight loss Roasting of sulphide ore 8 method 3

Study the rates of oxidation of Cu and mild steel in Kinetics of oxidation of copper 9 3 atmospheric air by the weight gain method Determination of decomposition voltage of aqueous of aqueous solution solutions of ZnSO 10 4 3 Determination of current efficiency by using aqueous solution of CuSO4.

MECHANICAL METALLURGY Course Course Name of Course L T P Credit Type Code DC FMC303 Mechanical metallurgy 3 0 0 9

Course Objective Fundamentals of deformation of materials in response to applied forces and introduction to metalworking operations Learning Outcomes • Fundamentals of elastic and plastic deformation. • Strengthening mechanisms in metals. • Failure mechanisms in metals. • Introduction to fracture mechanics. • Fundamentals and methods of metalworking.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Introduction and Elastic constants (atomistic origin), State Stress-strain relationships for elastic of stress in 2D/3D, Transformation of stress, Principal behaviour 1 3 stresses, Mohr Circle, Stress-strain relationships in isotropic and anisotropic materials Tensile test; engineering and true stress-strain curves; Introduction to the theory of plastic 2 4 ultimate tensile strength; toughness; ductile versus brittle deformation

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behavior; strain measurement; effect of strain rates; Von Mises and Tresca yield criteria for ductile materials Concept of Dislocations, Dislocations in the lattice, Understanding plastic deformation Burger Vector and its properties, Stress and Strain fields by dislocations of Dislocations, Energy of Dislocations, Forces on 3 4 dislocation, Motion of Dislocations, Concept of slip systems, Single crystal slip (critical resolved shear stress - CRSS) Strain hardening, Solid Solution Strengthening, Strengthening mechanisms in metals 4 Precipitation and Dispersion Strengthening, Grain 4 Boundary and Hall-Petch relation Introduction to fracture mechanics, Stress concentration, Fundamentals, characterization, and Crack growth criteria (Griffith, Irwin), Mode of mechanisms of fracture 5 4 deformation, Stress intensity factor, Fracture toughness, Classification of fracture and mechanisms Introduction to Fatigue, Few cases of fatigue failures, SN Failure of metals by fatigue curve, High and low cycle fatigue, Representation of 6 4 fatigue data, Fatigue crack propagation, Mechanisms of fatigue fracture Creep: Testing, Mechanisms: Diffusional related, Time-dependent deformation of 7 Dislocations related, Grain boundary sliding, Harper 2 metals at high temperatures Dorn, Power Law, Deformation Mechanism Maps Hardness Tests (Brinell, Rockwell, Vickers, knoop), Methods for measuring mechanical 8 2 Nanoindentation, Impact Testing properties Classification of forming processes; mechanics of Fundamentals of metalworking metalworking; Ideal work calculation; effect of 9 4 temperature and strain rates, friction and lubrication; formability; forming limit diagram Rolling; forging; extrusion; wire drawing; sheet metal Introduction to metalworking 10 8 working operations. Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Mechanical Metallurgy George E. Dieter McGraw Hill

COAL AND MINERAL PROCESSING PLANT DESIGN Course Course Name of Course L T P Credit Type Code DC FMC304 Coal and mineral processing plant design 3 0 2 11

Course Objective To give overall idea of coal and mineral processing plant design. Learning Outcomes Upon successful completion of this course, students will get project-based experiential learning of coal and mineral processing plant design, which includes flowsheet preparation, materials handlingand utility systems selection, contracts and project management and economics using software tools.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Introduction – BIS guidelines on flowsheet definitions and This unit will give students the symbols,Basic data required for plant flowsheet design. Plant general background of plant 1 6 capacity estimation, techno-economic feasibility design along with technical and calculations. Basic calculations like mass, water, grade, environmental aspects.

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energy balance. Environmental impact assessment during plant design. Mineral process plant flowsheets - Development of plant Understanding of flows sheet 2 flowsheets for mineral processing plants including iron, 8 design of mineral processing sulphide ore, mass, water and grade balancing. plants Coal preparation plant flowsheets - Development of plant Understanding of flows sheet flowsheets for thermal and metallurgical coals on single and design of coal preparation plants 3 7 composite (blended) feed basis including mass, water and ash balancing. Other plant flowsheets - Flowsheet development for beach Understanding of flows sheet 4 sand, rock phosphate, limestone, graphite, uranium ore etc. 4 design of strategic, nuclear, industrial minerals, etc. Material handling and utility system: General guidelines This will help students to on solid and liquid storage and transportation (belt conveyor understand the handling of solid, 5 and pumps). Selection and sizing of belt conveyors and 7 water and slurry along with pumps. Guidelines on selection of valves, pipes, bends, utilities used in plants. blower, compressor, cooling tower. Contracts and Project Management - Introduction to NIT Students shall be able to get the (Notice Inviting Tender), technical and commercial contract. idea handling contract, Steps of project award, Project costing, Basic and detail procurement, project costing, etc. 6 engineering, Purchase of equipment, Plant erection and 5 commissioning, Performance Guarantee Test. Mechanical, civil, structural, instrumentation, electrical aspects in plant design. Plant optimization and profitability calculations Engineering economics: Capital cost, operating cost, Knowledge related to economics 7 2 depreciation, return on investment of engineering Operational aspects of plant design - Project on plant This is practical work done by design, development of process flow sheet using MS Excel groups of students starting from 8 and ASPEN. Selection of equipment, mass/water/grade (26) material characterization to balancing, report submission. equipment selection, development of flowsheet, costing, etc. Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Andrew L. Mular, Roshan Society of Mining 1 Mineral Processing Plant Design Boman Bhappu Engineers (AIME) Mineral Processing Design and 2 A. Gupta and D.S. Yan Elsevier Operation: An Introduction Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Introduction to Mineral Processing Errol G. Kelly, David J. Spottiswood John Wiley and Sons

HEAT TREATMENT AND MECHANICAL METALLURGY LABORATORY Course Type Course Code Name of Course L T P Credit DC FMD 353 Heat Treatment and Mechanical Metallurgy laboratory 0 0 3 3

Course Objective The objective of the course is to understand correlation of equilibrium diagram, heat treatment, microstructure and mechanical properties of materials.

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LearningOutcomes Upon successful completion of this course, students will be able to draw heat treatment cycles and predict resultant microstructure and mechanical properties of steels and non-ferrous metals

Exp Contact Name of the experiment Learning Outcome No. Hours Preparation of specimens for microscopic examination – Understanding of basic process 1 steels, copper alloys and aluminium alloys; hot mounting and 3 for sample preparation cold mounting and mechanical fixtures. Microstructural study by etching of specimens of steel, Understanding of fundamentals 2 3 copper alloys and aluminium alloys and cast iron. of etching and microstructure Quantitative Metallography for phase volume fraction by This will help in quantifying 3 point counting and linear intercept method 3 volume fraction by different methods Estimation of phases and drawing of cooling curves for Fundamental of Fe-C transformation of plain carbon steels with varying carbon equilibrium phase diagram 4 3 contents using Fe-C diagram. Observation and description of microstructures of annealed plain carbon steels. Performing annealing, normalizing and hardening heat Understand the process of heat 5 treatment of steel samples; observation of microstructures 3 treatment and hardness. Hardenability determination by Jominy End Quench test as Understand the process of 6 per ASTM standard; estimation of hardenability using 3 hardenability determination composition of steel. Design of isothermal heat treatment cycle using TTT/CCT This will help in designing 7 3 diagram using fluidized bed and salt bath furnace. isothermal heat treatment cycle Performing surface heat treatments like carburizing, nitriding Practical understanding of heat 8 3 on steels; estimating resultant case depth. treatment and hardenability Observation and description of microstructure of typical Fundamental of microstructure 9 alloy steels such as micro-alloyed steel, dual phase steel, free 3 and property correlation cutting steel, bearing steel and maraging steel. Determination of the tensile properties of different class of Understanding of tensile 10 3 materials property of materials To study the strain aging behavior of steel (associated with Stain aging and yield point 11 the yield-point phenomena) using load-elongation curve 3 phenomenon obtained from tensile test To interpret ductile-brittle behavior of mild steel at various Impact testing of materials 12 temperature from the absorbed energy (indication of 3 (Charpy Impact Test) toughness) during impact To study the constant load creep behavior of Aluminium Understanding of Creep 13 3 property of materials To measure and compare the Brinell, Rockwell and Vickers Principle of hardness testing hardness of mild steel, aluminum and brass and comparison of different 14 3 hardness measurement techniques To study the effect of cyclic loading normally encountered Fatigue Testing 15 3 by the materials in service To study the effect of cold rolling on the tensile properties of Effect of work hardening on 16 3 aluminium the tensile properties of metals

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COMPUTATIONAL TECHNIQUES AND MODELLING Course Course Name of Course L T P Credit Type Code DE FME461 Computational techniques and modelling 3 0 0 9

Course Objective The objective of the course is to make the students aware of different approaches to be adopted for metallurgical accounting and computation of operational performances of Mineral processing plants and to know about the mathematical tools to be adopted for developing models for different operations/equipment and their application Learning Outcomes Upon successful completion of this course, students will • have a broad understanding of the approaches for carrying out material balancing of solid, water and slurries in two product separation systems. • the subject will give an insight on to the operating performances of size separation and beneficiation units • upon learning, the student will become conversant with minimization of errors involved in estimation of product yield and component recoveries after processing. • the subject will also make the students to become familiar of the different the optimization techniques to be adopted in operating plants.

Unit Lecture Topics to be Covered Learning Outcome No. Hours 1 Introduction, types of computations and Introduction to material balancing methodologies.Reconciliation of excess data for and other calculations 5 minimization of errors involved in yield and recovery calculations 2 Mass balancing of complex beneficiation circuits, concept Difficulties faced in mass balancing of connection matrix its main applications including of complex circuits and the component balancing; its uses and advantages, with constraints faced in operating plants 5 examples from Pb-Zn, iron ore, coal and beach sands besides making them to compute minimum number of streams to be sampled to perform mass balancing. 3 Reconciliation of excess data for minimization of errors Helps to understand how to optimize involved in yield and recovery calculations. 5 product yield and recoveries,

4 Statistically aided computation of errors involved in size This will help student in estimating and chemical analysis of feed and product streams for the extent of uncertainties and estimation of accurate yield in the plant operations ranges in which the fluctuation can Application of Lagrangian Multipliers to correct errors in 6 takes place in the data analysis and assay values feed, concentrate and tailing streams knowledge of the corrections can be made assay values of the components considered 5 Introduction to mathematical modelling, Types of models, This will help in understanding of their relative merits and demerits. Description on different techniques to be adopted empirical and semi empirical models. 4 for development of mathematical models in processing coal and mineral processing. 6 Modelling of size reduction processes, use of Matrix This unit will help the student the modelling for crushers and application of kinetic models approach of adoption of matrix and grinding mills. Description and application of modelling for comminution units Breakage, Selection Function and classification functions, considering size distribution 4 numerical examples for computing product distribution information of feed and products and using different models. the extent breakage took place Mathematical models for different processing equipment during comminution. and for partition curves

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7 Modelling of Flotation operations for batch and Helps to understand the kinetic continuous flotation. Kinetic approaches, different kinetic behavior of the process and through models, estimation of order of equation. Scale-up models 5 kinetics rate of flotability and based for continuous flotation using mechanical cells. Use of on flotability the size of flotation kinetic models for design of flotation circuits. circuit and size of the cell required., 8 Population balance models; Discrete Element Modelling Familiarisation with population 5 balance modelling and discrete element modelling Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher Modeling and Simulation of Mineral Processing 1 R. P. King Butterworth-Heinemann Systems Reference Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Introduction to Mineral Errol G. Kelly, David J. 1 John Wiley and Sons Processing Spottiswood Wills' Mineral Processing Society for Mining, Metallurgy and 2 Barry A. Wills James Finch Technology Exploration 3 Principles of Mineral Dressing Antoine Marc Gaudin McGraw Hill

PROCESS CONTROL AND PLANT LAYOUT Course Course Name of Course L T P Credit Type Code DE FMC462 Process control and plant layout 3 0 0 9

Course Objective To give concept of various control instruments, process control and plant layout Learning Outcomes Upon successful completion of this course, students will understand: • control instruments, control strategy adopted • equipment control, plant control operations and plant layout design

Unit Lecture Topics to be Covered Learning Outcome No. Hours Introduction: Need of process control, technical and economic Understanding of basic benefits. Fundamental Aspects-Recognition of dynamic nature of understanding of various 1 control operation; identification of controllable and non- 5 mineral processes and controllable operating variables; defining control objectives; process control. identification of process and plant constraints. Types of Control Actions: Feed Forward and feedback control; This unit will help student construction of a feedback controller; proportional action, integral in understanding the 2 5 action and derivative action; tuning of feedback controllers; various control actions. multiple input control; ratio control and cascade control. Instrumentation for measurement: On-line particle size This will help students in distribution, Metallurgical grade analysis and coal analysis; pulp understanding different 3 density, pulp level, froth level, slurry flow rate, ball mill load, 8 instruments used in pressure, temperature and other required measurements. controlling mineral processing plants. Control of plant operations: Crushing circuit, grinding circuit, This will enable students 4 15 flotation circuit, jig circuit and DMC circuit, dewatering and other to select and define

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allied operations. PLC and DCS control systems. Expert systems control strategy for a for plant control. Example of some actual implementation of plant. control systems in an operating plant and the control strategies used. Plant Layout: Introduction of Plot Plan, Contour, Concept of This will help students to levels, Floors, Location of equipment, etc. Design of Plant layout, understand the design of Building Layout, Equipment Layout. Input details required to equipment, building and 5 design a plant layout. Major points considered while designing a 6 plant layout. plant layout. Layout design of plant buildings - crushing, grinding, flotation, dewatering, etc. Introduction to piping layout. Role of civil and structural inputs in layout design. Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Society for Mining, Mineral Processing Plant Design, Practice, Andrew L. Mular, Doug N. 1 Metallurgy and and Control: Proceedings. Volumes I & II. Halbe, Derek John Barratt Exploration Mineral Processing Design and Operation: 2 A. Gupta and D.S. Yan Elsevier An Introduction Reference Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. SME Mineral Processing and Robert C. Dunne, S. Komar Kawatra, Society for Mining, 1 Extractive Metallurgy Handbook Courtney A. Young Metallurgy and Exploration 2 Introduction to Mineral Processing Errol G. Kelly, David J. Spottiswood John Wiley and Sons Wills' Mineral Processing 3 Barry A. Wills James Finch Butterworth-Heinemann Technology

NON-FERROUS EXTRACTIVE METALLURGY Course Course Name of Course L T P Credit Type Code DE FMD463 Non-ferrous Extractive Metallurgy 3 0 0 9

Course Objective The objective of the course is to provide the knowledge of extraction of non-ferrous metals from its ores. LearningOutcomes Upon successful completion of this course, students will: • have a broad understanding of principles of extraction of metals. • have a high-level understanding of process variables to enhance the productivity and efficiency of different processes. • be able to understand basic flowsheet of non-ferrous metal extraction.

Unit Lecture Topics to be Covered Learning Outcome No. Hours 1 Brief Introduction to Principles of metals extraction processes. 2 To recollects the basics. Introduction to extraction of non-ferrous metals, their sources. This will help the students to 2 General methods used for the extraction metals from sulphides, 2 understand the various oxides, hydroxides, native metals etc. methods/ routes and sources

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used in the extraction processes Extraction of metals from hydroxide/oxide minerals: Students will gain the Extraction of Aluminium, Bayer’s process for the production of knowledge of production of alumina and its under lying principles. Fused salt electrolysis, typical metals from factors affecting fused salt electrolysis Hall-Heroult process, role hydroxides/oxide by 3 of cryolite and mechanism involved in the process. Newer 8 different methods. Process for Aluminium production (ALCOA Process). Extraction of Tin, smelting and refining of tin concentrate. Extraction magnesium (PIDGEON and DOW Process), with reaction mechanisms involved in the processes. Extraction of metals from sulphides: This will enable the students Extraction of copper by conventional (roasting, smelting and to understand extraction of converting) process. Newer processes for copper extraction such base metals from their as Flash smelting, WORCRA and NORANDA processes. sulphides. Extraction of lead. Refining of lead bullion, Parke’s 4 desilverization. Modern development in . 10 Extraction of zinc, different methods involved in the process, Imperial Smelting Process, Condensation of zinc vapours, Roast leach electrolytic process. Extraction of nickel by pyrometallurgical process, hydrometallurgy of nickel sulphides concentrate. Extraction of Nuclear Metals. Hydrometallurgical Extraction of This portion will help in uranium by acid and alkali leaching. knowing the extraction of 5 Extraction of Titanium. Smelting of Ilmenite, Sorel Process. 8 nuclear metal and rare earth Production of Ti sponge by KROLLs Process. Extraction of rare metals. earth metals Production of precious metals. Extraction of gold and silver by Provides necessary cyanidation process and their under lying principles. Recovery fundamental and application 6 4 gold by reductive precipitation, CIP and CLL processes. of extraction of precious Extraction of platinum group of metals. metal from its native ores. By-product recovery from waste, such as ,and This will help knowing the 7 3 utilization. utilization of by-products. Flow sheets and general methods of refining, (Drossing, This will enable the students 8 Fractional distillation, Zone and fire refining.) 2 to the flow sheets and brush- up refining techniques. Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. H. S. Ray, R. Sridhar, K. P. Affiliated East-West 1 Extraction of Nonferrous Metals Abraham Press 2 Principles of Extractive Metallurgy H.S. Ray, A. Ghosh New Age International 3 Hydrometallurgy S. Venkatachalam Narosa Publication Hydrometallurgical Extraction and 4 Eric Jackson Ellis Horwood Reclamation Reference Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Pitman 1 Extractive Metallurgy W.H. Dennis Publishing

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Principles of Extractive Metallurgy, 2 Fathi Habashi CRC Press Volume 1 Tapir Academic 3 Principles of Extractive Metallurgy Terkel Rosenqvist Press John Wiley and 4 Non-Ferrous Production Metallurgy J. L.Bray Sons Unit Processes of Extractive 5 Robert D. Pehlke Elsevier Metallurgy Introduction to Melts: Molten Salts, 6 H. S. Ray Allied Publishers and Glasses Energy In Minerals & Metallurgical H. S. Ray, B. P. Singh, Sarama Bhattacharjee, 7 Allied Publishers Industries Vibhuti N. Misra

MINERAL POLICY AND ECONOMICS Course Course Name of Course L T P Credit Type Code DE FMD464 Mineral policy and economics 3 0 0 9

Course Objective To give concept of overall economics of coal and mineral processing plants Learning Outcomes Upon successful completion of this course, students will: • be able to understand Indian and global scenario of mineral processing activities • be able to understand plant economics that will help in designing the plant. • be able to understand the possible future technology.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Global scenario: World reserves of important minerals. Understanding of National and Different reserves classification systems e.g. UNFC, global scenario of mineral JORC. India's position in global mineral industry. reserves and key driving factors 1 6 Depletion of mineral resources and beneficiation for their technology. prospects.Future potential of key minerals and factors driving their demand Metal prices and markets. Production, consumption and Understanding of mineral markets 2 3 prices of minerals. Market structure of selected minerals. Indian Mineral Industry: This unit will help student in • Mineral reserves in India and classification system understanding the government adopted rules, environmental limitations • Contribution of minerals to Indian industrial and and other related aspects affecting economic growth. the mineral processing in India. • Roles & responsibility of key government 3 5 organisations managing the mineral sector: Policy framework in India • Domestic Demand and supply scenario of key minerals and metals. • Future scenario and steps required to meet future requirements Economics of mineral projects: This will help students in 4 • Typical cost components in a mineral project: Capital 10 understanding economic aspects costs, operating costs (fixed and variable costs) of plant design and operation.

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• Key financial aspects to evaluate feasibility of project - cost curve, profitability, Net Present Value, IRR and depreciation accounting Social and environmental assessment: This will enable students to Aspects for sustainable development of mineral understand social and 5 industry: environment, social, resource conservation, 8 environmental aspects of plant communityhealth, Life cycle assessment, environmental design and operation. audit, R-R-R approach for sustainability etc. This will help students to Future technologies for sustainable processing of coal, 6 7 understand the future minerals and metal recovery technologies. Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 An Introduction to Mineral Economics K. K. Chatterjee New Age International Reference Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Subhash C. Ray, Indra N. 1 Mine and Mineral Economics Prentice Hall Sinha Ore Geology, Economic Minerals and Mineral Atlantic 2 S. K. Tiwari Economics Publishers

IRON AND STEEL MAKING Course Course Name of Course L T P Credit Type Code DE FMD525 Iron and Steel Making 3 0 0 9

Course Objective The objective of the course is to provide the knowledge of iron making through blast furnace route as well as alternative routes, basic knowledge of steel making, secondary steel making and continuous casting. Learning Outcomes Upon successful completion of this course, students will: • have a broad understanding of iron making and steel making. • have a high-level understanding of process variables to enhance the productivity and efficiency blast furnace and alternative routes of iron making. • be able to understand basic layout of blast furnace, steel making shop and continuous casting process. • beable to control the cost of the steel by careful selection of the raw materials and other necessary ingredients required for steel manufacturing.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Raw-Materials: Iron ore quality w.r.t. size, chemistry and Understanding of iron making, other properties, Types of fluxes used and the importance of quality and quantity of raw 1 5 coke-quality for iron making. Requirement of Raw- materials required for the materials per tonne of Liquid Iron Production. production per tonne of hot metal. Agglomeration of Iron ore fines, Sintering; Principles, Understanding of iron bearing sintering bonds, sintering machines; Pelletisation; Theory of raw materials preparation for blast 2 Pelletisation, Water-particles system. Production of green 5 furnace feed especially when high pellets in; disk and drum pelletizers, Induration of pellets, grade ore is not availaboratoryle. Shaft, traveling grate and continues grate kiln machine.

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Overview of Blast furnace, six internal zones of blast Understanding of overview of the furnace, Blast furnace operation – Thermodynamic furnace, basic principles and 3 principles, refractories, temperature profile, aerodynamics, 6 problems occurs during operation high top pressure, different factors, irregularities etc. of blast furnace.

Blast furnace reactions, thermodynamics of -metal This will help is designing the reactions, oxygen enrichment, injection of steam, Blast blast furnace, reaction model and 4 furnace products - pig iron, top gas, slag & their utilization, 7 utilization by-products. cleaning of off gas, Blast furnace design & sizing, productivity, coke rate etc. Introduction to alternative iron making processes: Principles This unit will help student in of Sponge Iron Making, Degree of Metallization, understanding the alternative Percentage Reduction direct reduction process – DRI, HBI, route for iron making. Principles & technology of different coal based & gas based 5 6 direct reduction processes like Rotary kiln, Rotary hearth, Midrex, HyLetc Smelting Reduction Processes such as COREX, ROMELT, HiSmelt, Finexetc Steel making: Principles of steel making, Different methods This will help student in refining used such as L.D. Converter and Electric Furnaces. De- of hot metal and production steel. 6 6 oxidization of steel, uses of different types of de-oxidizers and alloys for different purposes. Secondary steel making, stainless steel making, Continuous Understanding of further refining 7 4 casting etc. of steel and giving a shape. Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 First Course in Iron and Steel Making Dipak Mazumdar Universities Press 2 Iron Making and Steelmaking: Theory and Practice Ahindra Ghosh, Amit Chatterjee Prentice Hall 3 Principles of Blast Furnace Ironmaking A.K. Biswas SBA Publications 4 Fundamentals of Steelmaking Metallurgy Brahma Deo, Rob Boom Prentice Hall 5 Fundamentals of Steelmaking E.T. Turkdogan Maney Publishing 6 Physical Chemistry of Melts in Metallurgy F.D. Richardson Academic Press Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 An Introduction to Modern Steel Making R.H. Tupkary, V.R. Tupkary Khanna Publishers 2 Extraction Metallurgy J. D. Gilchrist Pergamon Press 3 An Introduction to Modern Iron Making R.H. Tupkary, V.R. Tupkary Khanna Publishers

CEMENT TECHNOLOGY Course Course Name of Course L T P Credit Type Code DE FMD526 Cement technology 3 0 0 9

Course Objective The aim of this course is to provide fundamental knowledge about cement manufacturing processes and utilization of different types of fuels and raw materials in cement manufacturing. Learning Outcomes After attending the course students will be able to understand cement manufacturing process and role of various fuels in cement manufacturing. 1.

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Unit Lecture Topics to be Covered Learning Outcome No. Hours Various processes of cement manufacture – dry, semi- Overview of cement manufacturing 1 dry and wet, overview of various unit operations. 4 processes. Indian cement industry, the global scenario. Phase composition of clinker minerals and cement, pozzolanic reaction, hydration of cement, Raw mix proportioning, 2-, 3- and 4-component mixes, concepts Various reactions, raw materials and 2 15 of burn ability, absorption and effect of coal ash cement manufacturing methods. Different zones in a cement kiln, preheaters and pre- calcinators. Coolers, burners, fuels, waste-derived fuels, Pet coke, Various equipment and their design 3 8 refractory and refractory practices. aspects for cement manufacturing. 4 Testing of cements for various properties 4 Testing of cements. Approaches to energy conservation, energy audits, co- Various energy conservations 5 generation of power, Pollution control, noise 4 methodologies in cement plant. abatement, concepts of LCA. EIA and EMP. Quality control and plant layout of modern cement Students will know various quality 6 plants. 4 control methods in cement plant and plant layout. Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 The Chemistry of Cement and Concrete F. M. Lea Chemical Publishing Company Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Cement Data-book W.H. Duda Bauverlag GmbH Reinhold Publishing 2 The Chemistry of Portland Cement Robert Herman Bogue Corporation

WASTE PROCESSING AND MANAGEMENT Course Course Name of Course L T P Credit Type Code OE FMO543 Waste processing and management 3 0 0 9

Course Objective To give knowledge of waste generation from processing plants, characterization and utilization. Learning Outcomes Upon successful completion of this course, students will be able to get information of plant waste and its utilization in various industries.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Waste generation from processing plants, handling, storage and Students will be able to environmental hazards. identify the sources of 1 4 waste materials and their hazardous effects on environments. Characterization and utilization of solid wastes - red mud, steel Students will be able to 2 4 plant waste, fly ash waste, coal , etc. characterize the waste

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materials to identify their utilization potentials. Utilization of solid waste as building material, fertilizer, PVC Students will get products, paints, pigments, cement industries, brick making, knowledge about waste 3 coating, chemical industries, filtration, purification, etc. 10 materials from various industries and ways to utilize them. Composition and properties of slags from BF, LD, EAF, Cupola, Students will get Slag produced in Non-ferrous plants. Cements: type of slag, knowledge about waste granulation treatment, transportation, grinding, mixing & materials from 4 9 properties. Slag Wool: Type of slag, granulation, handling, metallurgical industries compaction. Slag Blast: properties & uses in Fertilizer industries, and ways to utilize them. Composition, treatment & application, Slag grinding. Properties: Composition, size, shape, surface properties, Students will get refractoriness, density. Applications: Building Brick – Binder knowledge about products selection, mixing, compaction, strengthening, Testing, generated from waste Equipments, economics. Insulation brick – Additives, compaction materials of various 5 12 firing and testing. Soil treatment – characteristic properties, uses, industries. Pozolana – Properties & testing Road Making – Properties & Testing, Horticultural Use, Effluent Treatment, Mine filling, Smelting, Other uses. Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Wealth From Waste: Agricultural, Food And Chemical Atlantic 1 S. C. Bhatia Processing Waste (Vol. 1) Publishers Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher Howard Peavy, Donald Rowe, 1 Environmental Engineering McGraw Hill George Tchobanoglous

CLEAN COAL TECHNOLOGY Course Course Name of Course L T P Credit Type Code DE FMO544 Clean coal technology 3 0 0 9

Course Objective The main aim of the course is to give fundamentals concept of efficient way of utilizing coal in different applications with minimum environmental impact. Learning Outcomes At the end of the course student will be able to identify various techniques of utilizing coal for cleaner environment.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Introduction to clean coal technology: Coal quality parameters Students will learn various for utilization in thermal power plant, cement, steel and DRI methods of coal cleaning 1 plant. Pre-combustion cleaning, during combustion cleaning, 10 methods and their merits post-combustion cleaning, burning time, unburned carbon and demerits. estimation and control. Biological and chemical cleaning

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methods. Emission control: Fly ash, SOx and NOx control strategies during Students will learn various combustion and after combustion. Use of ESP, Cyclones, Filters control strategies for 2 10 and settling chambers. CO2 sequestration. pollution control from coal based industries. Coal gasification: Gasifying agents: oxygen, air, steam, reactions Students will learn various involved in gasification. Effect of fuel properties on product, fundamentals of coal 3 8 blending of fuels. Syn gas, Fuel gas. gasification technologies will Types of gasifiers: Fixed bed, moving bed, fluidized bed, Students will understand entrained bed etc. Product gas cleaning and energy utilization, design and operation 4 5 removal of H2S, NH3, tar, suspended particulate matter. aspects of various types of gasifier. Other technologies: Underground coal gasification (UCG), Coal Students will learn other bed methane, recovery of methane from CBM (Coal Bed utilization aspects of coal 5 Methane), CMM (Coal Mine Methane), AMM (Abandoned Mine 6 and coal based gases. Methane), combined cycle power generation (IGCC), oxy-fuel combustion. Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Clean Coal Engineering Technology Bruce Miller Butterworth-Heinemann Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Fuels and Combustion Samir Sarkar Universities Press 2 The Chemistry and Technology of Coal James P. Speight CRC Press

EQUIPMENT DESIGN Course Course Name of Course L T P Credit Type Code DE FMO545 Equipment design 3 0 0 9

Course Objective The main objective of the course is to learn the methods of design of equipment used in various energy related operations Learning Outcomes At the end of the course, student will be able to theoretically design equipment and improves the understanding about the equipment

Unit Lecture Topics to be Covered Learning Outcome No. Hours Introduction to equipment design. Process flow diagram, Understanding of the material and energy balance, material of construction, prerequisites for equipment 1 6 properties of materials, corrosion due to high temperature, design corrosive atmosphere, abrasive material Design of cyclone separator, centrifuges, furnace, kiln, Knowledge of the design 2 fluidized bed reactor, pulverized combustion units, silos, 8 methodologies for various pressure vessel equipment/vessels Process design of shell and tube heat exchanger, Knowledge of the design 3 condenser, cooling tower. Mechanical design of shell & 8 methodologies for different heat tube heat exchanger exchangers 4 Design of tall vessels: Introduction, Axial stresses due to 8 Knowledge of the design of tall

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dead loads, Axial stresses due to pressure, Longitudinal vessels bending stresses due to dynamic loads, Design considerations of distillation (tall) and absorption column (tower) Process Hazards and Safety Measures in Equipment Understanding of the hazards and 5 Design: Process Hazards, Safety measures, Safety 9 safety measures to be considered measures in equipment design, Pressure relief devices during equipment design Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Joshi's Process Equipment Design V. V. Mahajani, S. B. Umarji Trinity Press Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Process Equipment Design S. D. Dawande Denett and Company 2 Relevant Indian Standards BIS BIS

ELEMENTS OF MINERAL ENGINEERING Course Course Name of Course L T P Credits Type Code OE FMO431 Elements of Mineral Engineering 3 0 0 9

Course Objective To learn about the principles and practices of different mineral engineering operations, in brief Learning Outcomes Upon successful completion of this course, students will have a brief knowledge of • the fundamentals of mineral engineering • the comminution and classification techniques applied in mineral engineering • the concentration techniques used in mineral engineering • the various dewatering techniques applied for ores and coal • the methods of hydrometallurgical extraction • the flowsheets of different ores and coal

Unit Lecture Topics to be Covered Learning Outcomes No. Hours Introduction: Scope, objectives and applications of Familiarisation with the basic 1 mineral processing; Liberation and beneficiation 4 introductory concepts of mineral characteristics of minerals and coal engineering Comminution: Theory and practice of crushing and Information about the fundamental 2 grinding; Different types of crushing and grinding 6 different comminution principles and equipment, their application equipment Size separation:Laboratory size analysis and Information about the basics of 3 interpretation; Settling of solids in fluids; Industrial 4 different classification principles and screens; Mechanical classifiers and hydrocyclones equipment Density separation methods: Jigging, dense medium Introduction to the different density- separation based concentration technologies 4 9 Spirals and Wilfley tables: theory, application and limitations. Froth flotation: Physico-chemical principles; Familiarisation with basics of froth 5 Reagents; Machines; Flotation of sulphides, oxides 6 flotation technology and coal.

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Electrical and magnetic methods of concentration: Introduction to the electrical and 6 4 Principles, fields of application and limitations. magnetic methods of concentration Knowledge of the fundamentals of 7 Dewatering: Thickening, filtration and drying. 4 dewatering Familiarisation with the conceptual Typical flow sheets:Coal, copper, lead-zinc, iron, 8 2 flowsheets of important ores and coal, beach sands, etc. employed in mineral engineering plants Text Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Wills' Mineral Processing Technology Barry A. Wills James Finch Butterworth-Heinemann Reference Books: S. No. Resource/Book Name Author(s)/Editor(s) Publisher 1 Principles of Mineral Dressing Antoine Marc Gaudin Tata McGraw Hill

CHARACTERIZATION OF MATERIALS Course Course Name of Course L T P Credit Type Code OE FMO541 Characterization of materials 3 0 0 9

Course Objective The objective of the course is to learn characterization of minerals and materials using various analytical instruments and data interpretation. Learning Outcomes Upon successful completion of this course, students will be able understand various characterization technologies for materials, analysis of results obtained from equipment and correlate them with the properties of materials.

Unit Lecture Topics to be Covered Learning Outcome No. Hours Introduction to material characterization, necessity of Students will be able to understand 1 characterization, methods of analysis 4 the necessity of characterization of materials and ways to analyze them. Materials characterization: importance and applications; Students will know various 2 principles of XRD, XRF. 4 characterization techniques based on X Ray. Microscopy techniques: optical and electrons (SEM, Students will know various 3 TEM, AFM) microscopy, QEMSCAN. 6 characterization techniques based on microscopic analysis. Introduction to spectroscopy (UV-vis, FTIR and Raman), Students will know various 4 HPLC. 4 characterization techniques based on spectroscopy. Thermal stability analysis: thermogravimetric analysis Students will know various thermal 5 4 (TGA) and differential scanning calorimetry (DSC). characterization techniques. Mechanical property characterization: principles and Students will know various 6 characterization of tensile, compressive, hardness, fatigue, 4 mechanical characterization and fracture toughness properties. techniques. Principles of characterization of other materials Students will know various properties: BET surface area; chemisorption; particle size; characterization techniques based on 7 13 zeta potential; rheology; and interfacial tension, FTIR, individual properties of materials. GCMS, LCMS, Ion Meters etc.

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Text Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Materials Characterization: Introduction to Microscopic Wiley-VCH Verlag 1 Yang Leng and Spectroscopic Methods GmbH and Co. Reference Books: S. Resource/Book Name Author(s)/Editor(s) Publisher No. Surface Characterization Methods: Principles, 1 Andrew J. Milling CRC Press Techniques, and Applications Materials Science and Engineering: An William D. Callister Jr., David G. John Wiley and 2 Introduction Rethwisch Sons

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