Course Structure M. Tech. Mineral Engineering With effect ... · merits and demerits of processing...

Course Structure: M. Tech, Mineral Engineering, Department of Fuel and Mineral Engineering, IIT(ISM) Dhanbad

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Course Structure

M. Tech. Mineral Engineering (Effective from Academic Year 2019-20)

Department of Fuel and Mineral Engineering

Indian Institute of Technology (ISM) Dhanbad

Dhanbad, Jharkhand, India

ANNEXURE – I


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SEMESTER - 1

Course No. Course Name L T P C

FMC 501 Coal and Mineral Processing 3 0 0 9

FMC 502 Transport Phenomena 3 0 0 9

FMC 503 Numerical methods & Computer Applications

3 0 0 9

FMC 504 Unit operations in Extractive Metallurgy

3 0 0 9

FMC 505 Size Enlargement Processes 3 0 0 9

FMC 551 Coal and Mineral Processing Practical 0 0 3 3

FMC 552 Extractive Metallurgy Practical 0 0 2 2

Total 15 0 5 50

SEMESTER - 2


FMC 507 Modelling, Simulation & Softwares 3 0 0 9

FMC 508 Process Equipment Selection 3 0 0 9

FMD 5xx Department Elective 1 3 0 0 9

Open Elective 1 3 0 0 9

Open Elective 2 3 0 0 9

FMC 554 MATLAB Practical 0 0 3 3

FMC 555 Coal preparation practical 0 0 2 2

Total 15 0 5 50

SEMESTER - 3


FMC 597 Thesis 0 0 0 36

Total 0 0 0 36

SEMESTER - 4

Course No.

Course Name L T P C

Department Elective-2/Open Elective 3 3 0 0 9

Department Elective-3/ Open Elective 4 3 0 0 9

FMC 598 Thesis Unit 5 0 0 0 18

Total 6 0 0 36


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Table 1. List of Department Core (DC): Theory Courses


FMC 501 Coal and Mineral Processing 3 0 0 9

FMC 502 Transport Phenomena 3 0 0 9

FMC 503 Numerical methods & Computer Applications

3 0 0 9

FMC 504 Unit Operations in Extractive Metallurgy 3 0 0 9

FMC 505 Size Enlargement Processes 3 0 0 9

FMC 507 Modelling, Simulation & Softwares 3 0 0 9

FMC 508 Process Equipment Selection 3 0 0 9

Table 2. List of Department Core (DC): Practical Courses


FMC 551 Coal and Mineral Processing Practical 0 0 3 3

FMC 552 Extractive Metallurgy Practical 0 0 2 2

FMC 554 MATLAB practical 0 0 3 3

FMC 555 Coal preparation practical 0 0 2 2

Table 3. List of Department Electives (DE)


FMD 521 Advanced Mineral Processing Technology

3 0 0 9

FMD 522 Coal Preparation 3 0 0 9

FMD 523 Plant flowsheet development & Practices

3 0 0 9

FMD 524 Beneficiation Process Control 3 0 0 9

FMD 525 Iron and Steel Making 3 0 0 9

FMD 526 Cement Technology 3 0 0 9

Table 4. List of Open Electives (OE) Offered by FME Dept.


FMO 541 Characterization of Materials 3 0 0 9

FMO 542 Mineral Processing Economics 3 0 0 9

FMO 543 Waste Processing and Management 3 0 0 9

FMO 544 Clean Coal Technology 3 0 0 9

FMO 545 Equipment design 3 0 0 9


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A. Syllabus of Department Core (DC): Theory Courses

1. COAL AND MINERAL PROCESSING (3-0-0 = 9)

Course objective: To impart fundamental understanding of various unit operations in coal

and mineral processing.

Course outcome: At the end of the course, the students would have understanding of the

various unit operations, equipments and beneficiation techniques for processing of coal and

minerals.

COURSE CONTENT MODULE 1: Introduction [4]

Necessity, scope, importance of coal and mineral processing. Important definitions: ore,

mineral, gangue, concentrate, tailing, yield, recovery and ratio of concentration etc.

Properties of different minerals relevant to their processing.

MODULE 2: Properties of solids and their handling [10]

Particle size, shape, specific surface area, density, shape factor, screen analysis, different

types of screens – static and dynamic, screening surfaces and screen efficiency, factors

influencing screen efficiency. Standard screen series, estimation of average particle size,

differential and cumulative particle size analysis, sampling of coal and minerals. Fundamentals

of size reduction, comminution laws, different types of crushers and grinding mills, their

features and application. Liberation of minerals, degree of liberation.

MODULE-3: Fluid-Particle interaction [4]

Movements of solids in fluid, Laws of settling, free settling, hindered settling. Classification -

types of classifiers, their principles and operations.

MODULE-4: Gravity Separation [8]

Different types of gravity separation-Principles, units, applications of dense media, Jigs,

flowing film concentrators, cyclones.

MODULE-5: Magnetic and electro-static separation [5]

Magnetic and electro-static separation: Principles, different types of magnetic and electrical

separators, their features and applications.

MODULE-6: Froth Flotation & dewatering [8]

Flotation theory, double layer of solid-liquid interface, zeta potential. Physics and chemistry

of interfaces, surface energy, interfacial tension and its role in flotation. Flotation reagents

and their importance. Characteristics of minerals and reagents, flotation applications in coal

and minerals. Dewatering – Flocculation, Thickening, filtration and drying. Leaching and

extraction.


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Text Books:

Mineral Processing Technology (B. A. Wills)

References: Introduction to Mineral Processing (Kelly and Spottiswood)

Principles of Mineral Dressing (A. M. Gaudin)

Coal Preparation (J. W. Leonard)

The Coal Handbook: Towards Cleaner Production (D. Osborne)

Coal preparation, Vol-1 and Vol-2, D. Osborne

2. TRANSPORT PHENOMENA (3-0-0 =9)

Course Objectives: The mail objective of the course is to learn the properties of fluid and its

transportation.

Course Outcome: At the end of the course, student will be able to understand the properties

of fluid and its transportation.

COURSE CONTENT: MODULE-1: Introduction, Transport Processes, Dimensional Analysis. [4] MODULE 2: Momentum Transfer: Steady and Unsteady Flows; Overall mass, energy and momentum balance; Navier Stokes equation; Newton’s Law, Non-Newtonian Fluids; Laminar flow in falling film, flow through conduits etc; Inviscid fluid flow, Viscous flow, Laminar and Turbulent Boundary Layer Theory, Friction Factor; Flow past immersed objects, packed and fluidized bed. [8]

MODULE 3: Mass Transfer: Steady state mass transfer and diffusion; molecular diffusion in gases, liquids, biological gels and solids; Unsteady state mass transfer under different conditions, mass transfer coefficient, diffusion through porous medium and capillaries; Boundary layer flow and turbulence in mass transfer, Simultaneous heat, mass and momentum transfer. [8]

MODULE 4: Heat Transfer: Conduction: Steady State: One Dimensional – Composite wall and cylinder; Multi-dimensional- Differential heat balance, shape factor, graphical and numerical methods.

Unsteady State: Analytical solutions of one dimensional lumped heat capacity system, heat flow in semi-infinite solid, convection boundary conditions, Heisler chart solutions.

Convection: Natural and forced convection, overall heat transfer coefficient, fouling factor, types of heat exchanges.

Radiation: Physical mechanism, radiation properties, shape factor, heat exchange between non-black bodies, infinite parallel planes, radiation shields, gas radiation. [10]

MODULE-5: Application of software (MatLab, CFD, FLUENT, ANSYS, etc.) in Transport Phenomena. [9]

Text Book:

G.H. Geiger and D.R. Poirier, TMS, Transport Phenomena in Metallurgy, Addison-Wesley, 1973

References:

R. Byron Bird, Warren E. Stewart, Edwin N. Lightfoot., Transport Phenomena 2nd Edition, John Wile and sons Pvt Ltd.


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3. NUMERICAL METHODS & COMPUTER APPLICATIONS (3-0-0 =9)

Course objective: The main aim of the course is to introduce the students to solve various

mathematical problems using numerical analysis with the help of MATLAB programming

Course outcome: At the end of this course students will be able to use MATLAB for various

modelling and simulations problems in engineering applications.

COURSE CONTENTS

MODULE-1: Basics of MATLAB programming, Array operations in MATLAB, Loops and

execution control, working with files: Scripts and Functions, Plotting and program output,

creating plots I Matlab. Matlab’s built in functions and User defined functions. [5]

MODULE 2: Defining errors and precision in numerical methods, Truncation and round-off

errors, Error propagation, Global and local truncation errors. Vectors and Matrix operations

in Matlab. [4]

MODULE-3: Linear algebra in MATLAB, Gauss Elimination, LU decomposition and partial

pivoting, Iterative methods: Gauss Siedel, Special Matrices: Tri-diagonal matrix algorithm.

Nonlinear equations in single variable, MATLAB function fzero in single variable, Fixed-point

iteration in single variable, Newton-Raphson in single variable, MATLAB functions for single

and multiple variables, Newton-Raphson in multiple variables. [4]

MODULE-4: Numerical Differentiation in single variable, Numerical differentiation of Higher

derivatives, Differentiation in multiple variables, Newton-Cotes integration formulae, Multi-

step application of Trapezoidal rule, MATLAB functions for integration. [4]

MODULE-5: Introduction, Linear least squares regression. Functional and nonlinear

regression, Interpolation in MATLAB using different functions. [4]

MODULE-6: Introduction to ODEs; Implicit and explicit Euler’s methods, Second-Order Runge-

Kutta Methods, MATLAB ode45 algorithm in single variable, Higher order Runge-Kutta

methods, Error analysis of Runge-Kutta method. Solution of ODE using Matlab. [6]

MODULE-7: Different types of Partial differential equations. Numerical solution of PDE using

Matlab. [4]

MODULE-8: Polynomial curve fitting. Curve fitting using Matlab and other techniques.

Mathematical computations and statistical analysis. [4]

MODULE-9: Applications of numerical methods in solving various mathematical equations of

Fuel and Mineral Engineering. Introduction to FEM, DEM, CFD software. [4]

Text Book:


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Pallab Ghosh, Numerical, Symbolic and Statistical Computing for Chemical Engineers Using MATLAB, Prentice Hall, 2018.

Reference Books:

W. Y. Yang, W. Cao, T. Chung, S. Chung and J. Morris, Applied Numerical Methods Using MATLAB, John Wiley, 2005

Constantinides and N. Mostoufi, Numerical Methods for Chemical Engineers with MATLAB Applications, Prentice Hall, 1999.

4. UNIT OPERATIONS IN EXTRACTIVE METALLURGY (3-0-0 =9)

Course objective: The objective of this course work is to provide knowledge of various metal

extraction process.

Course outcome: At the end of the course the students will be able to learn various metal

extraction processes, industrial practices, etc.

COURSE CONTENT:

MODULE-1: Pyro-metallurgy: Principles of pyro-metallurgy, Unit operations in pyro-

metallurgy, Calcination, Roasting, Smelting, Converting and Fire-refining. [8]

MODULE-2: Hydrometallurgy: Principles of hydro-metallurgy, Leaching, Solvent-

extraction, Iron Exchange, Cementation. [6]

MODULE-3: Electro-Metallurgy: Principles of electrolysis, Electro-winning and Electro

refining. [8]

MODULE-4: Extraction Processes of major Non-ferrous metals: Aluminium, Copper, Nickel,

Zinc, Lead, Titanium, Magnesium, Uranium, Gold and Silver. Including material preparation

and refining etc. Properties and uses of metals and their alloys for industrial applications.

[11]

MODULE-5: Iron and Steel making principles. Integration of above processes. Heat, mass and

overall energy balance in metallurgical operations. [6]

Text Books:

First Course in Iron and Steel Making by Dipak Mazumdar

Ahindra Ghosh, Amit Chatterjee, Iron Making and Steelmaking: Theory and Practice, PHI Learning Pvt. Ltd., 2008

References:

Principles of Extractive Metallurgy by A Ghosh and H S Ray

Extraction of nonferrous Metal by H. S. Ray, R. Sridhar and K.P. Abraham

H.S. Ray, R. Shreedhar and K.P. Abraham- Extraction of non-ferrous metals- affiliated East West press pvt. Ltd, Oscar Publications, New Delhi,2011.

S. Venkatachalam, Hydrometallurgy, Narosa Publishing House, 1998

Engineering in process metallurgy, R.I.L. GUTHRIE


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R D Pehlke, Unit Processes in Extractive Metallurgy- American Elsevier pub.Co.,Mishigan, 1973.

5. SIZE ENLARGEMENT PROCESSES (3-0-0=9)

Course Objective: The main aim of the course is to give fundamental concepts of size

enlargement process.

Course outcome: At the end of the course student will be conversant with the effective

utilization of ore fine in blast furnace and other applications.

COURSE CONTENT:

MODULE-1: Introduction to different size enlargement processes, necessity and scope of size

enlargement. Agglomeration: Fundamental forces of cohesion between particles, surface

tension, forces between micro assemblies, pore size distribution, pelletization, sintering and

other agglomeration methods – principles, mechanisms, use of additives, effect of induration

and assessment of quality of agglomerates, Blaine index. [8]

MODULE-2: Pelletization - Raw material preparation, Characteristics of raw materials for

pelletization, additives, binders etc. Green-ball formation, effect of process parameters on

size and strength of green-pellets, testing of Green-balls. Drying and firing of Green Balls,

testing of indurate pellets like Tumbler-test, Reducibility, Swelling index, Reduction

Degradation Index, Compressive strength etc. [10]

MODULE-3: Pelletization Equipment - Operation of Disc and Drum-Pelletizers, Different types

of pellet-firing system, Shaft-furnace, Grate-system and Grate Kiln System. Uses of pellets for

Blast Furnace and Direct Reduction Iron-making. [5]

MODULE-4: Sintering- various raw materials used for production of sinter. Preparation of fuel

mix and flux and their effect on the process of sintering. Calculation of charge-components

for producing desired quality of sinter to be used in Blast-Furnace for Iron making.

[5]

MODULE-5: Proportioning of Raw-materials, Primary and secondary mixing together with

Moistening, Sintering-Mineralogy, its effect on strength of sinter, Productivity of sintering

moisture, Control of various parameters for improving quality of product. [7]

MODULE-6: Briquetting, oil agglomeration, flocculation – Fundamentals, operating process,

design parameters and applications. [4]

Text Books:



References:

An Introduction to Modern Steel Making- R.H. Tupkary, Khanna publishers

Pelletizing of Iron ores – Kurt Meyer, Springer-Verlag 10980


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6.MODELLING, SIMULATION AND SOFTWARES (3-0-0=9)

Course objective: The main aim of the course is to give information about modelling and

simulations techniques used in various mineral and coal washeries.

Course outcome: At the end of the course, student will be able to optimize the processes and

theoretically analyze energy efficiency.

COURSE CONTENT:

MODULE-1: Introduction to the concept of mathematical modeling and simulations concepts

of distribution, population balance models. [10]

MODULE-2: Modeling of mineral engineering systems - crushing, grinding, hydrocyclones,

heavy media separation, Jigs, Tables, flotation and pelletization. Kinetic studies. [12]

MODULE-3: Simulation of plant flow sheets. [10]

MODULE-4: Learning of various software tools for modelling and simulation. [7]

Text Book:

A. M. Gaudin, Principles of Mineral Dressing, Tata McGraw-Hill, 1980

References:

R. Peter King, Modeling and Simulation of Mineral Processing Systems, Butterworth-

Heinemann, 2001

E. G. Kelly, D. J. Spottiswood, Introduction to Mineral Processing, Butterworth-Heinemann,

1982

7. PROCESS EQUIPMENT SELECTION (3-0-0=9)

Course Objective: The objective of this course is to give the concept of equipment selection.

Course outcome: At the end of the course student will be able to select an equipment for a

particular process.

COURSE CONTENT:

MODULE-1: Introduction, mass balance, water balance, grade balance and throughput

calculations for process unit operation. [3]

MODULE-2: Selection and sizing of crushers and screens. [7]

MODULE-3: Selection of grinding mills. [7]

MODULE-4: Estimation of number and size of flotation cells. [4]

MODULE-5: Selection of hydrocyclone, classifiers. [4]

MODULE-6: Outline of selection of gravity, magnetic and electrostatic separators. [6]


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MODULE-7: General outline of selection of water pump, slurry pump, froth pump, sump

pump. Application of DE system, DS system. Blower, Compressor, etc, in mineral processing

plants. Safety and statutory obligations in mineral processing plant design. [8]

Text Book:

Mineral processing plant design – Mullar and Bhappu.

References:

A.Gupta and D.S.Yan: Introduction to Mineral Processing Design and Operation.

E. G. Kelly, D. J. Spottiswood: Introduction to Mineral Processing.

B. Syllabus of Department Core (DC): Practical Courses

1. COAL AND MINERAL PROCESSING PRACTICAL

(0-0-3 = 3)

List of Practicals

1. Sampling - Bulk and sub-sampling, accuracy 2. Crushing characteristics of Jaw crusher, Roll crusher 3. Sieve and sub-sieve size analysis 4. Effect of different parameters on Ball mill grinding 5. Beneficiation using Mozley mineral separator 6. Beneficiation using Jig 7. Estimation of magnetics content by Davis tube magnetic separator 8. Beneficiation of copper ores using froth flotation

9. Beneficiation of lead-zinc ores using froth flotation 10. Beneficiation using Dry and wet high intensity magnetic separator 11. Beneficiation using Wilfley Table

2. EXTRACTIVE METALLURGY PRACTICAL (0-0-2 = 2)

List of Practicals

1. Estimation of Fe, SiO2, Al2O3 and LOI for a given iron ore

2. Effect of moisture on iron ore green pellet using disc pelletiser

3. Effect of bentonite on iron ore green pellet using disc pelletiser

4. Effect of rotation speed and angle of inclination of disc on green pellets production

5. Effect of moisture on iron ore green pellet using drum pelletiser

6. Effect of bentonite on iron ore green pellet using drum pelletiser

7. Roasting of sulphide ore

8. Calcination of limestone and dolomite

9. Magnetizing roasting of iron ore

10. Roast leaching of sulphide ore/ concentrate

11. Leaching of copper and lead zinc ore


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3.COAL PREPARATION PRACTICAL (0-0-2=2)

List of Practicals

1. Determination of HGI of coal

2. Proximate analysis of coal

3. Gross Calorific Value determination and Ultimate analysis of coal

4. Washability analysis of coal (2 classes)

5. Beneficiation of coal using jigging and performance analysis (2 classes)

6. Beneficiation of coal by spiral concentrator

7. Froth flotation of coal with assessment of the effect of the reagent dosage

8. Determination of flotation kinetics of coal

9. Selective Flocculation of coal fines

4.MATLAB PRACTICAL (0-0-3=3)

Solving various numerical problems of fuel and mineral application using MATLAB


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C. Syllabus of Department Electives (DE): Theory Courses

1. ADVANCED MINERAL PROCESSING TECHNOLOGY (3-0-0 =9)

Course objective: To get understanding of mineral beneficiation process and equipments.

Course outcome: At the end of the course, the students would be able to understand the

processing of mineral for the value addition and various equipments used.

COURSE CONTENT:

MODULE 1: Separation processes [2]

Principles, fluid particle interactions, different methods of separation.

MODULE 2: Comminution Equipment [7]

Crushers: forces of breakage, construction, operation, design and efficiency. Grinding mills:

Design, operation, maintenance and performance of Ball, Rod, AG, SAG and modern grinding

mills. Storage of solid- Bin, Bunker, Silo, etc. Classification: Mechanical and centrifugal

classifiers. Design, operation, performance of classifiers. Mathematical analysis and

quantification of comminution and classification processes. Recent developments.

MODULE-3: Gravity Separation [7]

Jigging: Design, construction, operational features of Jigs, Different applications of Jigs. Flow

film concentrators: Reichert cone concentrators, sluice separators, mineral spirals-design,

operation and performance. Dense media separation. Enhanced gravity concentrators -

multigravity separator, floatex density separator, Knelson concentrator, Kelsey jig, Falcon

separator etc. Recent developments.

MODULE-4: Magnetic and electrical separation [4]

Magnetic separators: Dry and wet, low and high intensity separators. High gradient and super

conducing separators. Electrical separation- Isodynamic separators, high tension separators.

MODULE-5: Flotation machines [8]

Function and types of flotation cell, design, their operation and applications, column and

Jameson cell. Performance on different minerals. Effects of various parameters: pH, pulp

density, reagent dose etc. Flotation circuits. Pumps for water and slurry transportation-

centrifugal pump, diaphragm pump and other auxiliary units. Recent developments.

MODULE-6: Alternate beneficiation techniques [2]

Selective flocculation, Oil agglomeration, Fluidization and other modern beneficiation

techniques. Recent developments.


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MODULE-6: Dewatering [4]

Thickeners, filtration units for minerals, drying. Application and performance. Recent

developments.

MODULE-7: Mineral processing flowsheets. [5]

Processing circuits for iron, copper, lead, zinc. Industrial minerals, uranium, chromite, beach

placer etc.

Text Book:





2. COAL PREPARATION (3-0-0 =9)

Course objective:

To learn the characteristics of coal relevant to its preparation

To identify the different unit operations used for the preparation of coal for its utilization in thermal power plants and coke ovens

Course outcome:

At the end of the course, the students would be able to

Understand the cleaning of coarse coal and fine coal.

Carry out the performance analysis of coal beneficiation equipment

Get orientation of industrial coal preparation flowsheets.

COURSE CONTENT:

MODULE 1: INTRODUCTION & COAL WASHABILITY [10]

Coal formation, coal geology, types of coal and coal properties. Proximate analysis, HGI, GCV.

Necessity, scope and application of coal preparation. Sink - Float tests and washability studies.

MODULE-2: CRUSHING AND SCREENING OF COAL [9]

Crushers for coal. Rotary breaker, Roll crushers, Impact group of crushers, Sizers, etc.

Pulveriser, Ball mill, Screening. Impact of Particle size distribution on coal washing. Industrial

screens. Performance evaluation of crusher, mills and screens. Overview of coal handling

circuit in coal washeries.

MODULE-3: GRAVITY SEPARATION OF COAL [10]

Jigging, Dense medium separation, Dense media bath, Dense media cyclone. Dry

beneficiation of coal. Choice between the washers. Performance evaluation: Partition curve,

misplacement, probable error in separation, imperfection, yield reduction factor, organic

efficiency.


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MODULE-4: FINE COAL CLEANING & DEWATERING [7]

Fine coal cleaning using Spirals, water only cyclones, froth flotation. Dewatering - Centrifuges,

thickeners, cyclones and filters.

MODULE-5: COAL PREPARATION PRACTICES [3]

Typical flowsheets for preparation of metallurgical (coking) and thermal (non-coking) coal.

Text Book:

Coal Processing Technology (D. G. Osborne) References:


The Coal Handbook: Towards Cleaner Production (D. Osborne)

The Principles of Coal Preparation (G. J. Sanders)

3. PLANT FLOWSHEET DEVELOPMENT AND PRACTICES (3-0-0=9)

Course Objective: The main aim of the course is to give a knowledge of coal and mineral

processing plant practices and associated flowsheet development.

Course outcome: At the end of the course student will be able to understand practices of

different coal and mineral processing plants, flowsheet development, plant operation.

COURSE CONTENT:

MODULE-1: Introduction, data and information required for flowsheet development and

plant design, Site selection, BIS definition. [4]

MODULE-2: Beneficiation of minerals such as lead, zinc, copper, uranium, etc . [13]

MODULE-3: Beneficiation of iron ore. [6]

MODULE-4: Beneficiation of industrial minerals, beach sand minerals, etc. [6]

MODULE-5: Coking and non-coking coal washing practices. [6]

MODULE-6: Troubleshooting of common mineral/coal processing plant problems. [4]

Text Book:

Mineral processing plant design – Mullar and Bhappu.

References:

Mineral Processing Plant Design, Practice, and Control: by Andrew L. Mular, Doug N.

Halbe, Derek J. Barratt.

A.Gupta and D.S.Yan: Introduction to Mineral Processing Design and Operation.

Barry A. Wills, Tim Napier-Munn: Mineral Processing Technology.

E. G. Kelly, D. J. Spottiswood: Introduction to Mineral Processing.

http://www.amazon.in/s/ref=dp_byline_sr_book_1?ie=UTF8&field-author=Andrew+L.+Mular&search-alias=stripbooks

http://www.amazon.in/s/ref=dp_byline_sr_book_2?ie=UTF8&field-author=Doug+N.+Halbe&search-alias=stripbooks

http://www.amazon.in/s/ref=dp_byline_sr_book_2?ie=UTF8&field-author=Doug+N.+Halbe&search-alias=stripbooks

http://www.amazon.in/s/ref=dp_byline_sr_book_3?ie=UTF8&field-author=Derek+J.+Barratt&search-alias=stripbooks


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4.BENEFICIATION PROCESS CONTROL (3-0-0=9)

Course objective: To give concept of various control instruments, process control and plant

layout.

Course outcome: The students will be able to understand control instruments, control

strategy adopted, plant control operations, plant layout design.

COURSE CONTENTS

MODULE-1: Introduction- Need of process control, technical and economic benefits.

Fundamental Aspects-Recognition of dynamic nature of control operation; identification of

controllable and non-controllable operating variables; defining control objectives;

identification of process and plant constraints. [6]

MODULE-2: Types of Control Actions: Feed Forward and feedback control; construction of a

feedback controller; proportional action, integral action and derivative action; tuning of

feedback controllers; multiple input control; ratio control and cascade control. [6]

MODULE-3: Instrumentation for measurement: On-line particle size distribution,

Metallurgical grade analysis and coal analysis; pulp density, pulp level, froth level, slurry flow

rate, ball mill load and other required measurements. [8]

MODULE-4: Control of plant operations: Crushing circuit, grinding circuit, flotation circuit,

dewatering and other allied operations. PLC and DCS control systems. Expert systems for

plant control. Example of some actual implementation of control systems in an operating

plant and the control strategies used. [13]

MODULE-5: Plant Layout: Introduction of Plot Plan, Contour, Concept of levels, Floors,

Location of equipment, etc. Design of Plant layout, Building Layout, Equipment Layout. Input

details required to design a plant layout. Major points considered while designing a plant

layout. Layout design of plant buildings - crushing, grinding, flotation, dewatering, etc.

Introduction of piping layout. Role of civil and structural inputs in layout design. [6]

Text Book:





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5. IRON AND STEEL MAKING (3-0-0 =9)

Course Objective: The objective of this course is to provide the principle of extraction of metal

from its ores.

Course outcome: At the end of the course student will be able to learn raw material

preparation for extraction of iron making and steel making.

COURSE CONTENT:

MODULE-1: Raw-Materials: Iron ore quality w.r.t. size, chemistry and other properties, Types

of fluxes used and the importance of coke-quality for iron making. Requirement of Raw-

materials per tonne of Liquid Iron Production. [5]

MODULE-2: Sintering and pelletization of Iron-ore fines and usage of Sinter/ Pellets, Iron

bearing burden and its importance. [6]

MODULE-3: Production of Pig Iron: Construction of Blast-Furnace, use of refractories, Cooling

of various plants. B.F aerodynamics, various reactions taking place in different zones,

Composition of slag and its effects on the quality of metal produced. [9]

MODULE-4: The parameters affecting the productivity of Blast-Furnace. Irregularities' in blast

furnaces, de-sulphurization and de-phosphorization of Pig-Iron. [5]

MODULE-5: D.R Processes: Raw material preparation. Quality requirement and consumption

norms Different methods of Sponge Iron Production. Scope of the process under Indian

condition. S-R Processes: Production of liquid iron by SR process – such as COREX, ROMELT,

Mini Blast - Furnaces and Electric Furnaces. [8]

MODULE-6: Steel making: Principles of steel making, Different methods used such as L.D.

Converter and Electric Furnaces. De-oxidization of steel, uses of different types of de-oxidizers

and alloys for different purposes. [6]

Text Books:



References:

An Introduction to Modern Steel Making, R.H. Tupkary, Khanna publishers

J. D. Gilchrist- Extractive metallurgy- Pergamon Press, 1989.

W. G. Davenport, M. King, M. Schlesinger, A. K. Bishwas and - Extractive metallurgy of Copper,4th ed., Pergamon Press,2002.


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6. 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 in cement manufacturing.

Course outcome: After attending the course students will be able to understand cement

manufacturing process and role of various fuels in cement manufacturing.

COURSE CONTENTS

Module 1: Various processes of cement manufacture – dry, semi-dry and wet, overview of

various unit operations. Indian cement industry, the global scenario. [4]

Module 2: Phase composition of clinker minerals and cement, pozzolanic reaction, hydration

of cement, Raw mix proportioning, 2-, 3- and 4-component mixes, concepts of burn ability,

absorption and effect of coal ash Different zones in a cement kiln, preheaters and pre-

calcinators. [15]

Module 3: Coolers, burners, fuels, waste-derived fuels, Pet coke, refractory and refractory

practices. [8]

Module 4: Testing of cements for various properties. [4]

Module 5: Approaches to energy conservation, energy audits, co-generation of power,

Pollution control, noise abatement, concepts of LCA. EIA and EMP. [4]

Module 6: Quality control and plant layout of modern cement plants. [4]

Text Book:

Chemistry of Cement and Concrete: F M Lea, Arnold, London

References:

Cement Data Book: W. H Duda , Verlag G m Bh, Berlin, R. H. Bouge.

Chemistry of Portland Cement, Reinhold, New York


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C. Syllabus of Open Electives offered by FME

1. CHARACTERIZATION OF MATERIALS (3-0-0=9)

Course objective: The aim of this course is to enable students for characterization studies and

its significance.

Course outcome: The students will be able to do characterization studies and understand

their relevance in beneficiation of particular ore.

COURSE CONTENT:

MODULE-1: Introduction to material characterization, necessity of characterization, methods

of analysis. [4]

MODULE-2: Materials characterization: importance and applications; principles of X-ray

diffraction (XRD), XRF. [4]

MODULE-3: Microscopy techniques: optical and electrons (SEM, TEM, AFM) microscopy. [6]

MODULE-4: Introduction to spectroscopy (UV-vis, FTIR and Raman), HPLC. [4]

MODULE-5: Thermal stability analysis: thermogravimetric analysis (TGA) and differential

scanning calorimetry (DSC). [4]

MODULE-6: Mechanical property characterization: principles and characterization of tensile,

compressive, hardness, fatigue, and fracture toughness properties. [4]

MODULE-7: Principles of characterization of other materials properties: BET surface area;

chemisorption; particle size; zeta potential; rheology; and interfacial tension, FTIR, GCMS,

LCMS, Ion Meters etc. [13]

Books/References:

Text Book:

Y. Leng, Materials Characterization: Introduction to microscopic and spectroscopic methods,

1st Ed., John Wiley & Sons, 2008.

References:

A.J. Milling, Surface Characterization Methods: Principles, techniques, and applications,

Marcel Dekker, 1999.

W.D. Callister (Jr.), Material Science and Engineering: An introduction, 8th Ed., John Wiley &

Sons, 2010. 7. Laboratory Instruction Manual

2. MINERAL PROCESSING ECONOMICS (3-0-0=9)

Course Objective: To give knowledge of all aspects of the mineral industry and to assess

Indian mineral reserves and resources.

Course outcome: This will enable students to get current information about the industry


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COURSE CONTENT:

MODULE-1: Global scenario [6]

World reserves of important minerals

Different reserves classification systems e.g. UNFC, JORC

India's position in global mineral industry

Depletion of mineral resources and beneficiation prospects.

Future potential of key minerals and factors driving their demand. MODULE-2: Indian Mineral Industry [10]

Mineral reserves in India and classification system adopted

Contribution of minerals to Indian industrial and economic growth.

Roles & responsibility of key Government organisations managing the mineral sector: Ministry of Mines, Ministry of Coal, Indian Bureau of Mines, Coal Controller Organisation, DGMS, state departments

Major industrial revolutions and its impact on mineral industry.

Domestic Demand and supply scenario of key minerals and metals.

Policy framework in India - Mineral Sector Policies, Exploration Policies, Steel Policy, MMDR and Rules framed thereunder, mineral auctions, etc.

Future scenario and steps required to meet future requirements MODULE 3: Economics of mineral projects [10]

Typical cost components in a mineral project: Capital costs, operating costs (fixed and variable costs)

Key financial aspects to evaluate feasibility of project - cost curve, profitability, Net Present Value, IRR

MODULE-4: Aspects for sustainable development of mineral industry: environment, social, resource conservation, health, Life cycle assessment, etc. [6] MODULE-5: Future technologies for mineral beneficiation. [7]

Text Book:

An introduction to mineral economics by K K Chatterjee.

References:

Mine and mineral economics by Subhash C. Ray and Indra N. Sinha.

Ore geology, economic minerals and mineral economics by S K Tiwari

3.WASTE PROCESSING AND MANAGEMENT (3-0-0=9)

Course Objective: To give knowledge of waste generation from processing plants,

characterization and utilization.

Course outcome: This will enable students to get information of plant waste and its utilization

in various industries.


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COURSE CONTENT:

MODULE-1: Waste generation from processing plants, handling, storage and environmental

hazards. Characterization and utilization of solid wastes - red mud, steel plant waste, fly ash

waste, iron ore, copper, lead, zinc, coal tailings, etc. [8]

MODULE-2: Utilization of solid waste as building material, fertilizer, PVC products, paints,

pigments, cement industries, brick making, coating, chemical industries, filtration,

purification, etc. [10]

MODULE-3: Composition and properties of slags from BF, LD, EAF, Cupola, Slag produced in

Non-ferrous plants. Cements: type of slag, granulation treatment, transportation, grinding,

mixing & properties. Slag Wool: Type of slag, granulation, handling, compaction. Slag Blast:

properties & uses in Fertilizer industries, Composition, treatment & application, Slag grinding.

[11]

MODULE-4: Properties: Composition, size, shape, surface properties, refractoriness, density.

Applications: Building Brick – Binder selection, mixing, compaction, strengthening, Testing,

Equipments, economics. Insulation brick – Additives, compaction firing and testing. Soil

treatment – characteristic properties, uses, Pozolana – Properties & testing Road Making –

Properties & Testing, Horticultural Use, Effluent Treatment, Mine filling, Smelting, Other uses.

[10]

Text Book:

Sustainable solid waste collection and management, By Ana Pires, Graça Martinho,

Susana Rodrigues, Maria Isabel Gomes

4. CLAEAN 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.

Course outcome: At the end of the course student will be able to identify various techniques

of utilizing coal for cleaner environment.

COURSE CONTENTS

Module 1: Introduction to clean Fuel technology: Coal quality parameters for utilization in

thermal power plant, cement, steel and DRI plant. Pre-combustion cleaning, during

combustion cleaning, post-combustion cleaning, burning time, unburned carbon estimation

and control. Biological and chemical cleaning methods. [10]

Module 2: Emission control: Fly ash, SOx and NOx control strategies during combustion and

after combustion. Use of ESP, Cyclones, Filters and settling chambers. CO2 sequestration.

[10]


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Module 3: Coal gasification: Gasifying agents: oxygen, air, steam, reactions involved in

gasification. Effect of fuel properties on product, blending of fuels. Syn gas, Fuel gas. [8]

Module 4: Types of gasifiers: Fixed bed, moving bed, fluidized bed, entrained bed etc.

Product gas cleaning and energy utilization, removal of H2S, NH3, tar, suspended particulate

matter. [5]

Module 5: Other technologies: Underground coal gasification (UCG), Coal bed methane,

recovery of methane from CBM (Coal Bed Methane), CMM (Coal Mine Methane), AMM

(Abandoned Mine Methane), combined cycle power generation (IGCC), oxy-fuel combustion.

[6]

Text Book:

1. Clean Coal Engineering Technology: Bruce G Miller, Elsevier Publications.

References:

1. Fuels and Combustion: Samir Sarkar, University Press (India) Pvt Limited, India.

2. The Chemistry and Technology of Coal: James G Speight, Marcel Dekker.

5. EQUIPMENT DESIGN (3-0-0=9)

Course Objectives: The main objective of the course is to learn the methods of design of

equipment used in various unit operations.

Course Outcome: At the end of the course, student will be able to theoretically design

euipments and improves the understanding about the equipment.

COURSE CONTENTS

MODULE-1: Introduction to equipment design. Process flow diagram, material and energy

balance, material of construction, properties of materials. [6]

MODULE-2: Design of cyclone separator, Centrifuges, furnace, kiln, fluidized bed reactor,

pulverized combustion units, silos, pressure vessel. [8]

MODULE-3: Process Design of Heat Exchanger: Types of heat exchanger, Process design of

shell and tube heat exchanger, Condenser, and reboilers. Mechanical design of heat

exchanger: Mechanical design of shell & tube heat exchanger. [8]


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MODULE-4: Design of tall vessels: Introduction, Axial stresses due to dead loads, Axial stresses

due to pressure, Longitudinal bending stresses due to dynamic loads, Design considerations

of distillation (tall) and absorption column (tower). [8]

MODULE-5: Process Hazards and Safety Measures in Equipment Design: Process Hazards,

Safety measures, Safety measures in equipment design, Pressure relief devices. [9]

Text Book:

1. V.V. Mahajani, S.B. Umarji, Joshi's Process Equipment Design, Laxmi Publications; Fifth edition

(2016)

Reference:

1. S. D. Dawande, Process Equipment Design Vol. 1 (7th Edition)

*******

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