MSE 522

Rate Phenomena in Process Metallurgy

Sem. 1. Class 3, cr. 3. (offered in alternate years). Prerequisite: senior or graduate standing in engineering or science.

MSE 522 is an elective course.

Weekly Schedule: Three 50-minute lectures.

Rates of metallurgical processes with engineering application to process simulation and control. Special attention to processes important to iron and steelmaking. Homogeneous and heterogeneous reaction kinetics. Mass and energy transport. Steady-state and nonsteady-state reaction systems. Development of process models. Offered in alternate years.

Relation of Course to Program Outcomes
1. an ability to apply knowledge of mathematics, science, and engineering to problems in materials engineering.
5. an ability to identify, formulate, and solve engineering problems, particularly in the context of materials selection and design.

Goals
To utilize the fundamentals of thermodynamics, chemical kinetics, and transport phenomena to develop quantitative descriptions of reaction systems encountered in the production and processing of inorganic materials. Topics include:

• Thermodynamics: methods of solution and graphical representation for the final state of heterogeneous reaction systems.
• Reaction kinetics: mechanisms, rate-controlling steps, and rate expressions for single-phase and heterogeneous systems.
• Reaction systems: transport phenomena, phase transformations, and chemical reactions in heterogeneous reaction systems. Development of differential equations to describe process variables as a function of time and position.
• Introduction to process models: formulation, solution, and validation. Introduction to numerical techniques.

Course Objectives
Upon completion of this course the student is expected to:
• Use Gibbs phase rule to organize the solution of multicomponent, multiphase equilibrium systems.
• Formulate the equations needed for solution of multicomponent, multiphase equilibrium systems.
• Employ spreadsheet or math package programs for algebraic solution or graphical representation of equilibrium systems. Examples: heat-treating atmospheres, combustion atmospheres, heterogeneous gas-solid systems.
• Employ an understanding of reaction mechanisms and rate-controlling steps to formulate rate expressions for single-phase and heterogeneous reaction systems. Examples: High-temperature gas phase reactions; Gas-solid reactions with applications to oxidation/reduction reactions, carbothermic reduction, roasting, carburization; Solid-solid reactions with applications to nucleation and growth.
• Explain the different types of reacton systems encountered in the production and processing of inorganic materials. Steady-state and non-steady-state; open and closed systems; batch, semi-batch, and continuous flow systems with specific industrial examples.
• Formulate differential balances on species and energy as a function of time and/or position for various reactor configurations.
• Formulate differential continuity equations on chemical species with a production term to describe reaction kinetics.
• Formulate differential balances for heat transfer with phase transformation. Applications to solidification, melting, ablation, vapor deposition.
• Formulate differential balances for heterogeneous reaction systems with a condensed phase of variable composition. Applications to diffusion, convection, solute redistribution in solidification; refining reactions, staged contacting patterns.
• Integrate (solve) differential balances as a function of position for reaction systems at steady-state: concurrent and countercurrent contacting patterns. Analytical and numerical (computer) solution techniques.
• Integrate (solve) differential balances as a function of time for position-independent systems: stirred-tank, fluidized bed. analytical and numerical (computer) solution techniques.
• Integrate (solve) differential balances as a function of time and position. Examples: Non-steady state mass diffusion and heat conduction.
• Understand the techniques employed in the development of process models: formulation, solution, and validation.

Instructor(s)
Robert Spitzer

Contribution of course to meeting the professional component:MSE 522 is a materials-specific technical elective course.

Prepared by: Elliott Slamovich                                                            Date: April 25th, 2007